CN108184332A - 用于光伏电池模块背接触的复合系统 - Google Patents
用于光伏电池模块背接触的复合系统 Download PDFInfo
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Abstract
本发明涉及一种用于光伏电池模块背接触的复合系统,其由具有导体电路结构的金属箔和至少一层电绝缘且稳定的聚合物层组成,该聚合物层施加在金属箔上并且与金属箔以粘合的方式连接在一起。稳定的聚合物层的主要目的在于使得结构化的导体电路机械稳定,从而在出现例如由于在层压过程中或运行时出现的温度升高而触发的剪切力时使导体电路不移动。
Description
技术领域
本发明涉及一种用于光伏电池模块背接触(back contacting)的复合系统,该复合系统由具有导体电路结构的金属薄箔和至少一层电绝缘且稳定的聚合物层构成,该聚合物层施加在金属薄箔上并且与所述金属薄箔粘合地(adhesively)连接在一起。
背景技术
在光伏电池模块(PV模块)中,组合使用具有不同热机械特性,如热膨胀系数和弹性系数的材料(玻璃、电池单元Si、金属、由塑料层组成的嵌入材料)。
通常来说,在真空层压过程中制造PV模块,在该过程中,在温度和压力的作用下,各个塑料层彼此连接。不同材料的不同热机械特性则导致在模块中出现压力,这产生了在各个层之间的剪切力。
在使用背接触的电池单元时,为了连接电池单元通常使用大面积的互连结构(interconnect structures),因为这些互连结构允许减少欧姆损失。已知的是,例如所谓的“传导背板”,例如在文献EP 2 810 539 A1或文献EP 2 618 381 A1中所描述的。例如,专利申请文献WO 2011 003969 A2中描述了一种用于PV模块的复合系统,其中,所述复合系统由承载箔、施加至承载箔上的金属箔和绝缘层组成,所述绝缘层施加到所述金属薄箔上并且防止电池单元与金属箔之间的短路。除了良好的电绝缘值之外,该绝缘层也具有机械屏障的功能,这阻止了电池单元的金属背侧的导电颗粒或不平坦部分被推过绝缘层并且因此引起短路。
现有技术中已知的PV模块的缺点在于,根据用于绝缘层的塑料的选择或如果存在承载层的情况下对承载层的塑料的选择,这些条件在真空层压过程(尤其升高的温度)会导致所提及的层的过度软化。通过不同的热膨胀系数在层之间产生的力,则可导致导体电路在金属层之间相对于彼此移动并且甚至彼此接触,并且由此触发短路。此外,绝缘层可在局部失去其屏障特性,这可导致在导体电路与电池单元背侧之间的短路。
太阳能模块的美感在,例如建筑集成领域中具有重要意义。在模块中其中一个最重要的光学特征就是颜色。因此,能够对从电池单元的间隙中的前部可见的绝缘层或导体电路进行染色将是有利的。
发明内容
因此,本发明的目的在于提供一种用于PV模块背接触的复合系统,其防止导体电路在金属层中移动以及绝缘层失去屏障功能,由此,避免短路的出现。另一个目的在于,给出了这种可行性,即,制造一种PV模块,其满足了所希望的连续着色的要求并且绝缘层和导体电路在颜色上不再彼此不同。
为了解决现有技术中已知的问题,本发明现在提出了一种在制造PV模块时用于接触的特殊的复合系统。
根据本发明的用于光伏电池模块背接触的复合系统,该复合系统包括:金属箔,该金属箔具有导体电路结构;以及至少一层电绝缘且稳定的聚合物层,该聚合物层施加在金属箔上并且与金属箔粘合地连接在一起。稳定的聚合物层的主要目的在于使得结构化的导体电路机械稳定,从而在出现剪切力时(例如由于在层压过程中或运行时出现的温度升高而触发)阻止结构化的导体电路移动。
根据本发明,优选地是,复合系统额外地还包括聚合物复合体(polymercomposite),其至少由两层聚合物层组成。一方面,该聚合物复合体应具有密封性,即与光伏电池形成一粘合连接(adhesive connection)。此外,聚合物复合体具有屏障功能并且实现了复合系统的电绝缘。
在一优选的实施方式(自下部向上部系统(Bottom-Up system),图1)中,稳定的聚合物层放置在金属箔(导体层)之后(下部)并且通过另一聚合物复合体(上部)来增补,所述聚合物层布置在导体层与电池单元之间,聚合物层借助密封层将电池单元粘合地彼此连接,确保了导体层与电池单元之间的电绝缘。借助屏障层确保了机械屏障功能,这阻止了电池单元的导电背面的导电颗粒或不平坦部分被推过。特别来说,该屏障功能用于在金属包裹(MWT)电池单元(metal wrap through cells)的背侧不平坦的情况下。
在另一优选的实施方式(上部系统(Up-system),图2)中,稳定的聚合物层是聚合物复合体的一部分,其直接施加在金属箔上。除了稳定导体电路之外,聚合物复合体也确保了电池单元的电绝缘并提供了屏障功能。
聚合物复合体的电绝缘的聚合物层的主要目的在于,机械上保护结构化的导体电路在机械上免受温度影响。
为此使用的聚合物层的流动特性以及热学特性确保在制造PV模块或在运行时的温度变化期间的导体电路的机械稳定性,并且确保,不会产生机械的屏障功能的局部损失,使得可避免短路。
电池单元端子与导体电路之间的电接触通过相应的聚合物复合体的开口来确保,其中,出于该目的,在开口中安装有连接件(bonding means)。
开口通过热学机械过程、化学或通过激光方法来产生。在此,必须确保聚合物复合体与制造过程的兼容性。
除此之外,重要的是,复合系统的不同部件与不同模块材料的兼容,例如:封装、玻璃、导体胶水、焊料和太阳能电池。此外,这些部件应满足模块长时间稳定性的整体要求。
为了确保机械稳定性和/或机械的屏障功能而使用的聚合物层在这样的温度情况下,如在层压或在运行期间出现的温度,不会过度软化。为此,该聚合物层具有这样的软化温度,该软化温度处于层压温度窗口之外。特别有利的是,聚合物具有的玻璃化温度也在该层压窗口之外。此外,该聚合物层尽可能不具有吸水性,因为在一些聚合物中,潮湿作为塑化剂起作用。
用于机械稳定或作为机械屏障的稳定的聚合物层,优选地由下列聚合物中的至少一个组成:聚酯、聚酰胺、聚酰亚胺、醋酸纤维素、聚甲醛、聚氯乙烯、聚苯乙烯、聚醚酮、聚环氧化物、聚丙烯酸酯、聚丙烯腈、聚氨酯和其卤素衍生物或改性的聚合物。
能够用作屏障的另一可选的聚合物层由下列聚合物中的至少一个组成:改性聚硅氧烷、环氧树脂、聚碳酸酯、聚酰胺、聚丙烯酸酯、聚丙烯腈、聚甲基丙烯酸甲酯、聚酯和其卤素衍生物以及改性的聚合物。
用作密封层的另一的聚合物层优选由下列聚合物中的至少一个组成:聚乙烯乙酸乙烯酯、聚乙烯醇缩丁醛、聚苯乙烯、聚氯乙烯、热塑性聚烯烃或其衍生物、改性的聚合物。
在一个优选的实施方式中,密封的聚合物层具有高于150℃的软化温度,并且所述密封的聚合物层不具有在50℃与150℃之间的玻璃化温度,优选为不具有在50℃与120℃之间的玻璃化温度,并且在从50℃到150℃之间的温度区域中,所述密封的聚合物层的弹性含量大于塑性含量。
根据本发明优选的是,与金属箔直接接触的聚合物层形成为粘合层,并且优选为可交联的粘合层,且不具有在50℃与150℃之间的玻璃化温度。
在本发明的一个有利的实施方案中,聚合物层形成为粘合层并且包括下列聚合物中的至少一种:环氧树脂、聚丙烯酸酯、改性聚硅氧烷、聚乙烯醇缩丁醛、交联的聚乙烯乙酸乙烯酯、聚环氧化物或聚氨酯。
金属箔优选由铜制成。金属箔也可以由铝、锡或锡合金、镀锡薄膜或银制成。在一有利的实施方案中,金属箔具有至少5μm,优选为5-60μm并且特别优选为10-40μm的厚度。
附图说明
在图1中示出了根据本发明的第一实施方式(自下部往上部)的薄膜系统(foilsystem)的典型结构。在此,图1a示出了具有金属箔染色的典型的结构,图1b示出了染色的塑料薄膜的结构。
具体实施方式
在此,使用了稳定的聚合物层(下部),以实现导体电路结构的机械稳定性。聚合物层与导体电路的连接通过连接剂来实现。所述连接剂优选地为粘合剂。
所使用的粘合剂为可交联的粘合剂,并且给薄膜系统提供机械固定性。机械上稳定的并且通过温度激活的连接剂防止由于在层压过程中产生的剪切力引起的薄膜系统的变形,并且相应防止导体电路相互移动。因此,本发明可防止由这种移动产生的短路。
根据本发明的粘合层优选为下列聚合物中的至少一种:环氧树脂、聚丙烯酸酯、改性聚硅氧烷、聚乙烯醇缩丁醛或交联的聚乙烯乙酸乙烯酯、聚环氧化物或聚氨酯。
所提出的复合系统的另一优点在于染色的可行性,因此在电池单元空隙中的前部可见的绝缘层或导体电路不会再带有颜色地镶嵌在模块中。可在导体电路或在聚合物层复合体中进行染色,聚合物层复合体作为绝缘层或机械屏障(上部)。染色可通过层压、喷涂、蒸发、溶胶-凝胶方法、印刷、上釉、雾化来进行。
在对导体电路进行染色的时候,使用聚合物基体(polymer matrices)(优选为一种聚合物基体),该聚合物基体也用作屏障或电绝缘层。无机的颜料是颜料的主要成分并且通常嵌入聚合物基体中或施加在聚合物基体上。
此外,所描述的对导体电路进行染色还具有另外的优点,即,其额外地作为电绝缘和/或机械屏障。
目前的自下部-往上部复合系统可将稳定功能(下部)和机械屏障(上部)去耦合并且连接系统可由两个部分制成。在制造根据本发明的复合系统时,该功能的去耦合实现了很高的灵活性。在另一有利的实施方案中,稳定的聚合物层和作为屏障的聚合物层因此位于两个独立的薄膜复合体(foil composites)中。
同样,因此本发明也包括一种制造用于光伏电池模块背接触的复合系统的方法,其中,各个薄膜复合体的制造分别进行。
根据本发明的复合系统的另一优点体现在PV模块的制造。即已知的是,在制造太阳能电池模块时,通过背接触使金属-聚合物层复合系统卷起,使得在制造模块期间难以应用电池单元。该现象和聚合物层与导体电路之间的不同的膨胀系数有关。利用根据本发明的复合系统,可避免该不利的效应。
在另一优选的实施方式中(上部系统),用于导体电路的稳定功能、电池单元与导体电路之间的电绝缘和机械屏障功能被组合在聚合物复合体中,所述聚合物复合体与导体层连接在一起并且在层压期间产生了与电池单元背面的粘合连接。
在图2中示出了两个示例性的实施方案,其中,图2a和图2b示出了两层薄膜复合体,以及图2c和图2d示出了三层薄膜复合体。
在两层薄膜复合体中,聚合物复合体由两个不同的聚合物层和粘合层组成。在三层聚合物复合体中,至少由两个不同的聚合物层组成。
在根据图2a和图2b的两层薄膜复合体中,直接布置在导体电路上的聚合物层构造成机械上稳定的、电绝缘的、具有机械屏障功能的聚合物层。借助连接剂实现了在金属箔上粘合上聚合物层。所述连接剂优选为粘合剂。
使用的粘合剂为可交联的粘合剂,并且因此给予由聚合物复合体和导体层形成的薄膜系统机械坚固性。根据本发明的粘合剂优选为至少下列聚合物中的一种:环氧树脂、聚丙烯酸酯、改性聚硅氧烷、聚乙烯醇缩丁醛或交联的聚乙烯乙酸乙烯酯、聚环氧化物或聚氨酯。
朝向电池单元的聚合物层构造成粘合层,并且在层压期间将薄膜系统与电池单元连接在一起。
起到绝缘、机械稳定和形成机械屏障的聚合物层具有软化温度并且特别有利地也具有玻璃化温度,其处于层压温度窗口之外并且尽可能不吸水。优选地,聚合物层由下列聚合物中的至少一种组成:聚酯、聚酰胺、聚酰亚胺、醋酸纤维素、聚甲醛、聚氯乙烯、聚苯乙烯、聚醚酮、聚环氧化物、聚丙烯酸酯、聚丙烯腈、聚氨酯和其卤素衍生物或改性的聚合物。
根据图2c和图2d的三层薄膜复合体中,稳定聚合物层通过粘合聚合物与导体层连接,所述粘合聚合物由下列聚合物中的至少一种组成:聚乙烯乙酸乙烯酯、聚乙烯醇缩丁醛、聚苯乙烯、聚氯乙烯或热塑性聚烯烃、其衍生物或改性的聚合物。有针对性地来选择稳定聚合物层的流变性能,例如动态粘度、损耗模量、储能模量、玻璃化温度,使得在模块制造中的真空层压过程期间保持稳定性。
此外,两层薄膜复合体和三层薄膜复合体应具有对封装、玻璃、导体粘合剂和太阳能电池的特别的化学兼容性。此外,聚合物层必须满足关于太阳能电池模块的长时间稳定性的要求。特别是,必须考虑在温度变化时的电池单元背面和/或触点上的应力。
同样可行的是,在该第二实施方式中对聚合物层进行染色。然而,这必须与背接触的太阳能电池单元的制造过程兼容。
附图标记
1 稳定的聚合物层(聚酯、聚酰胺、聚酰亚胺、醋酸纤维素、聚甲醛、聚氯乙烯、聚苯乙烯、聚醚酮、聚环氧化物、聚丙烯酸酯、聚丙烯腈、聚氨酯和其卤素衍生物、改性的聚合物)
2 粘合层(环氧树脂、聚丙烯酸酯、改性聚硅氧烷、聚乙烯醇缩丁醛、交联的聚乙烯乙酸乙烯酯、聚环氧化物、聚氨酯)
3 聚合物层(聚丙烯酸酯、改性聚硅氧烷、环氧树脂、聚碳酸酯、聚酰胺、聚丙烯酸酯、聚丙烯腈、聚甲基丙烯酸甲酯、聚酯和其卤素衍生物、改性的聚合物)
4 聚合物层(聚乙烯乙酸乙烯酯、聚乙烯醇缩丁醛、聚苯乙烯、聚氯乙烯、热塑性聚烯烃或其衍生物、改性的聚合物)
10 金属箔(Cu、Al、Ag、Sn)
11 染色
20 光伏电池单元
Claims (14)
1.一种用于光伏电池模块背接触的复合系统,包括:
-金属箔,其具有导体电路结构;以及
-至少一层电绝缘且稳定的聚合物层,其施加在所述金属箔上并且与所述金属箔粘合地连接在一起。
2.根据权利要求1所述的用于光伏电池模块背接触的复合系统,还包括聚合物复合体,所述聚合物复合体由至少两层聚合物层组成。
3.根据权利要求1或2所述的用于光伏电池模块背接触的复合系统,其特征在于,所述稳定的聚合物层放置在所述金属箔的后面,并且由至少三层聚合物层组成的所述聚合物复合体施加在所述金属箔上。
4.根据权利要求1或2所述的用于光伏电池模块背接触的复合系统,其特征在于,所述稳定的聚合物层是聚合物复合体的一部分,其直接施加在所述金属箔上并且同时构成热机械屏障。
5.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,
-所述稳定的聚合物层由下列聚合物中的至少一种组成:聚酯、聚酰胺、聚酰亚胺、醋酸纤维素、聚甲醛、聚氯乙烯、聚苯乙烯、聚醚酮、聚环氧化物、聚丙烯酸酯、聚丙烯腈、聚氨酯和其卤素衍生物或改性的聚合物;和/或
-密封的聚合物层由下列聚合物中的至少一种组成:聚乙烯乙酸乙烯酯、聚乙烯醇缩丁醛、聚苯乙烯、聚氯乙烯、热塑性聚烯烃或其衍生物、改性的聚合物。
6.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述作为屏障的聚合物层由下列聚合物中的至少一种组成:聚丙烯酸酯、改性聚硅氧烷、环氧树脂、聚碳酸酯、聚酰胺、聚丙烯酸酯、聚丙烯腈、聚甲基丙烯酸甲酯、聚酯和其卤素衍生物以及改性的聚合物。
7.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,
-所述密封的聚合物层具有高于150℃的软化温度,以及
-所述密封的聚合物层不具有在50℃与150℃之间的玻璃化温度,优选为不具有在50℃与120℃之间的玻璃化温度,以及
-在从50℃到150℃之间的温度范围内,所述密封的聚合物层的弹性含量大于塑性含量。
8.根据上述权利要求中任一项所述的用于光伏电池模块进行背接触的复合系统,其特征在于,与所述金属箔直接接触的所述聚合物层形成为粘合层,优选为可交联的,并且不具有在50℃与150℃之间的玻璃化温度。
9.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述粘合层由下列聚合物中的至少一种组成:环氧树脂、聚丙烯酸酯、改性聚硅氧烷、聚乙烯醇缩丁醛、交联的聚乙烯乙酸乙烯酯酯、聚环氧化物、聚氨酯。
10.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述复合系统在聚合物基体内或上方包含一层无机颜料。
11.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述金属箔由铜、铝或银、或锡或锡合金、或镀锡薄膜组成。
12.根据上述权利要求中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述金属箔具有大于5μm,优选5-60μm,并且特别优选为10-40μm的厚度。
13.根据上述权利要求1-3和5-12中任一项所述的用于光伏电池模块背接触的复合系统,其特征在于,所述稳定的聚合物层和所述作为屏障的聚合物层位于两个独立的薄膜复合体中。
14.一种用于制造根据权利要求13所述的复合系统的方法,其特征在于,各个薄膜复合体的制造是分别进行的。
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CN201680058387.3A Pending CN108184332A (zh) | 2015-08-12 | 2016-08-02 | 用于光伏电池模块背接触的复合系统 |
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US (1) | US20180240925A1 (zh) |
EP (1) | EP3335247A1 (zh) |
JP (1) | JP2018523318A (zh) |
KR (1) | KR20180039707A (zh) |
CN (1) | CN108184332A (zh) |
DE (1) | DE102015113297A1 (zh) |
WO (1) | WO2017025386A1 (zh) |
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ITVI20120264A1 (it) * | 2012-10-10 | 2014-04-11 | Ebfoil S R L | Backcontact-backsheet per moduli fotovoltaici comprendenti uno strato primer |
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2015
- 2015-08-12 DE DE102015113297.4A patent/DE102015113297A1/de not_active Withdrawn
-
2016
- 2016-08-02 WO PCT/EP2016/068429 patent/WO2017025386A1/de active Application Filing
- 2016-08-02 KR KR1020187007022A patent/KR20180039707A/ko unknown
- 2016-08-02 CN CN201680058387.3A patent/CN108184332A/zh active Pending
- 2016-08-02 JP JP2018527004A patent/JP2018523318A/ja active Pending
- 2016-08-02 EP EP16748108.4A patent/EP3335247A1/de not_active Withdrawn
- 2016-08-02 US US15/752,165 patent/US20180240925A1/en not_active Abandoned
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US20130240036A1 (en) * | 2010-11-12 | 2013-09-19 | Fujifilm Corporation | Back sheet for solar cell and process for production thereof, and solar cell module |
EP2643418A2 (en) * | 2010-11-23 | 2013-10-02 | Adhesives Research, Inc. | Reactive conductive pressure-sensitive adhesive tape |
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Also Published As
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US20180240925A1 (en) | 2018-08-23 |
KR20180039707A (ko) | 2018-04-18 |
JP2018523318A (ja) | 2018-08-16 |
WO2017025386A1 (de) | 2017-02-16 |
EP3335247A1 (de) | 2018-06-20 |
DE102015113297A1 (de) | 2017-02-16 |
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