CN108215358B - 一种太阳能电池背板及其制备方法 - Google Patents

一种太阳能电池背板及其制备方法 Download PDF

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CN108215358B
CN108215358B CN201810002942.1A CN201810002942A CN108215358B CN 108215358 B CN108215358 B CN 108215358B CN 201810002942 A CN201810002942 A CN 201810002942A CN 108215358 B CN108215358 B CN 108215358B
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张军
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Suzhou Yuanlian Technology Pioneer Park Management Co ltd
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Abstract

本发明提供一种太阳能电池背板及其制备方法。该太阳能电池背板的制备方法包括：1)在第一、第二、第三金属基板中分别形成多个过孔；2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理；3)依次层叠氟树脂外耐候层、第一金属基板、氟树脂‑橡胶复合层、第二金属基板、橡胶‑EVA复合层、第三金属基板以及EVA层；4)进行热压合处理，以得到所述太阳能电池背板。该方法制备的太阳能电池背板具有优异的密封性能、绝缘性能以及散热性能，进而可以提高相应太阳能电池组件的抗PID性能。

Description

一种太阳能电池背板及其制备方法
技术领域
本发明涉及太阳能电池技术领域，特别是涉及一种太阳能电池背板及其制备方法。
背景技术
晶体硅太阳能电池由于效率高、制造工艺成熟而得到广泛的应用。相应的晶体硅太阳能组件通常包括钢化玻璃、胶层、电池片层、胶层以及太阳能电池电池背板，太阳能电池背板位于太阳能电池组件的背面，对电池片起保护和支撑作用，具有可靠的绝缘性、阻水性、耐老化性。现有的太阳能电池背板通常分为两种：一种为涂胶复合式背板膜，在PET聚酯薄膜两面复合氟膜或者EVA胶膜，三层结构，常见的有TPT、TPE、KPK等结构。一种为涂覆背板膜，在PET聚酯薄膜两面涂覆氟树脂，经干燥固化成膜。
潜在电势诱导衰减(PotentialInducedDegradation，PID)是太阳能电池组件的一种特性，指在高温多湿环境下，高电压流经太阳能电池单元便会导致输出下降的现象。然而现有的太阳能电池背板的导热性能相对较差、密封性能相对较差，进而导致其不具备抗PID性能。如何提高太阳能电池背板的导热性能和密封性能，进而提高相应太阳能电池组件的抗PID性能，其引起了人们的广泛关注。
发明内容
本发明的目的是克服上述现有技术的不足，提供一种太阳能电池背板及其制备方法。
为实现上述目的，本发明提出的一种太阳能电池背板的制备方法，包括以下步骤：1)在第一金属基板、第二金属基板以及第三金属基板中分别形成多个过孔；2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理；3)在所述第一金属基板的下表面铺设氟树脂外耐候层，在所述第一金属基板的上表面铺设氟树脂-橡胶复合层，接着在所述氟树脂-橡胶复合层上铺设所述第二金属基板，接着在所述第二金属基板的上表面铺设橡胶-EVA复合层，接着在所述橡胶-EVA复合层上铺设所述第三金属基板，接着在所述第三金属基板的上表面铺设EVA层；4)进行热压合处理，使得所述氟树脂外耐候层、所述氟树脂-橡胶复合层、所述橡胶-EVA复合层以及所述EVA层各自的一部分进入与上述各层分别相邻的金属基板的各个过孔中，以得到所述太阳能电池背板。
作为优选的，所述步骤2)中的所述干燥处理的温度为70-120℃以及时间为50-90秒。
作为优选的，所述步骤4)中的热压合处理的具体工艺为：在100-120℃的温度下，以压力增加速率为每分钟增加1-3Kg/cm2的条件将压力增至15-20Kg/cm2，保持10-20分钟，接着以压力增加速率为每分钟增加4-6Kg/cm2的条件将压力增至40-50Kg/cm2，保持20-30分钟，接着以压力降低速率为4-6Kg/cm2的条件将压力降至15-20Kg/cm2，保持5-10分钟，接着以压力降低速率为1-2Kg/cm2的条件将压力降为0，然后在50-80℃的条件下固化70-100小时,最后冷却至室温。
作为优选的，所述氟树脂外耐候层包括：氟树脂100份，导热纳米颗粒10-20份，玻璃纤维5-10份。
作为优选的，所述氟树脂-橡胶复合层包括：氟树脂60-80份，橡胶60-80份；导热纳米颗粒20-30份；碳纤维10-20份。
作为优选的，所述橡胶-EVA复合层包括：橡胶50-70份，EVA40-60份，导热纳米颗粒10-20份；碳纤维10-15份。
作为优选的，所述EVA层包括：EVA100份，导热绝缘纳米颗粒10-20份，玻璃纤维10-15份。
作为优选的，所述第一、第二、第三金属基板中的多个过孔呈矩阵排列，过孔的直径为3-5毫米，相邻过孔之间的间距为5-10毫米。
本发明还提供了一种太阳能电池背板，所述太阳能电池背板为采用上述方法制备形成的。
本发明的太阳能电池背板包括三个金属基板，且每个金属基板中均具有多个过孔，且在每个金属基板的上下表面的树脂层通过过孔粘结在一起，各树脂层中均具有导热纳米颗粒，且通过优化过孔的直径和间距，提高树脂层与金属板之间的粘结性能，使得该太阳能电池背板具有优异的密封性能、绝缘性能以及散热性能，进而可以提高相应太阳能电池组件的抗PID性能，此外金属基板之间具有氟树脂-橡胶复合层以及所述橡胶-EVA复合层，使得该太阳能电池背板具有优异的抗震性能，有效减少相应太阳能电池组件由于碰撞导致损坏的几率。此外，本发明的制备方法与现有技术相比还具有如下有益效果：通过优化热压合处理工艺，压力采用先逐渐增加压力，并进行阶段性热压处理，然后再逐渐降低压力，使得在整个热压合过程中太阳能电池背板的受力更均匀，进而制备的太阳能电池背板的致密性更高、综合性能更优越，本发明的制备方法简单，易于工业生产。
附图说明
图1为本发明的太阳能电池背板的结构示意图。
图2为本发明的太阳能电池背板中的金属基板的俯视结构图。
具体实施方式
一种太阳能电池背板的制备方法，包括以下步骤：1)在第一金属基板、第二金属基板以及第三金属基板中分别形成多个过孔；2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理；3)在所述第一金属基板的下表面铺设氟树脂外耐候层，在所述第一金属基板的上表面铺设氟树脂-橡胶复合层，接着在所述氟树脂-橡胶复合层上铺设所述第二金属基板，接着在所述第二金属基板的上表面铺设橡胶-EVA复合层，接着在所述橡胶-EVA复合层上铺设所述第三金属基板，接着在所述第三金属基板的上表面铺设EVA层；4)进行热压合处理，使得所述氟树脂外耐候层、所述氟树脂-橡胶复合层、所述橡胶-EVA复合层以及所述EVA层各自的一部分进入与上述各层分别相邻的金属基板的各个过孔中，以得到所述太阳能电池背板。
其中，所述步骤2)中的所述干燥处理的温度为70-120℃以及时间为50-90秒。所述步骤4)中的热压合处理的具体工艺为：在100-120℃的温度下，以压力增加速率为每分钟增加1-3Kg/cm2的条件将压力增至15-20Kg/cm2，保持10-20分钟，接着以压力增加速率为每分钟增加4-6Kg/cm2的条件将压力增至40-50Kg/cm2，保持20-30分钟，接着以压力降低速率为4-6Kg/cm2的条件将压力降至15-20Kg/cm2，保持5-10分钟，接着以压力降低速率为1-2Kg/cm2的条件将压力降为0，然后在50-80℃的条件下固化70-100小时,最后冷却至室温。所述氟树脂外耐候层包括：氟树脂100份，导热纳米颗粒10-20份，玻璃纤维5-10份。所述氟树脂-橡胶复合层包括：氟树脂60-80份，橡胶60-80份；导热纳米颗粒20-30份；碳纤维10-20份。所述橡胶-EVA复合层包括：橡胶50-70份，EVA40-60份，导热纳米颗粒10-20份；碳纤维10-15份。所述EVA层包括：EVA100份，导热绝缘纳米颗粒10-20份，玻璃纤维10-15份。所述第一、第二、第三金属基板中的多个过孔呈矩阵排列，过孔的直径为3-5毫米，相邻过孔之间的间距为5-10毫米，所述第一、第二、第三金属基板的材质优选为铝或铜。
本发明还提供了一种太阳能电池背板，所述太阳能电池背板为采用上述方法制备形成的。如图1-2所示，所述太阳能电池背板包括氟树脂外耐候层1、第一金属基板2、氟树脂-橡胶复合层3、第二金属基板4、橡胶-EVA复合层5、第三金属基板6以及EVA层7，第一金属基板2、第二金属基板4以及第三金属基板6均具有多个过孔8，所述氟树脂外耐候层1、所述氟树脂-橡胶复合层3、所述橡胶-EVA复合层5以及所述EVA层7各自的一部分进入与上述各层分别相邻的金属基板的各个过孔8中，上述各树脂层在各过孔8中相互粘结在一起。
实施例1：
一种太阳能电池背板的制备方法，包括以下步骤：
1)在第一金属基板、第二金属基板以及第三金属基板中分别形成多个过孔，所述第一、第二、第三金属基板中的多个过孔呈矩阵排列，过孔的直径为4毫米，相邻过孔之间的间距为8毫米，所述所述第一、第二、第三金属基板的材质为铝；
2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理，所述干燥处理的温度为100℃以及时间为60秒；
3)在所述第一金属基板的下表面铺设氟树脂外耐候层，在所述第一金属基板的上表面铺设氟树脂-橡胶复合层，接着在所述氟树脂-橡胶复合层上铺设所述第二金属基板，接着在所述第二金属基板的上表面铺设橡胶-EVA复合层，接着在所述橡胶-EVA复合层上铺设所述第三金属基板，接着在所述第三金属基板的上表面铺设EVA层，其中，所述氟树脂外耐候层包括：氟树脂100份，导热纳米颗粒15份，玻璃纤维8份。所述氟树脂-橡胶复合层包括：氟树脂70份，橡胶70份；导热纳米颗粒25份；碳纤维15份。所述橡胶-EVA复合层包括：橡胶60份，EVA50份，导热纳米颗粒15份；碳纤维12份。所述EVA层包括：EVA100份，导热绝缘纳米颗粒15份，玻璃纤维12份；
4)进行热压合处理，热压合处理的具体工艺为：在110℃的温度下，以压力增加速率为每分钟增加2Kg/cm2的条件将压力增至18Kg/cm2，保持15分钟，接着以压力增加速率为每分钟增加5Kg/cm2的条件将压力增至48Kg/cm2，保持25分钟，接着以压力降低速率为5Kg/cm2的条件将压力降至18Kg/cm2，保持7分钟，接着以压力降低速率为2Kg/cm2的条件将压力降为0，然后在70℃的条件下固化80小时,最后冷却至室温，使得所述氟树脂外耐候层、所述氟树脂-橡胶复合层、所述橡胶-EVA复合层以及所述EVA层各自的一部分进入与上述各层分别相邻的金属基板的各个过孔中，上述各树脂层在各过孔中相互粘结在一起，以得到所述太阳能电池背板。
将上述方法制备的太阳能电池背板进行性能测试，结果表明，其与太阳能电池组件EVA胶层的剥离强度为150N/cm，水汽透过率为0.15g/m2*d，导热系数为19.58W/m*k。
实施例2：
一种太阳能电池背板的制备方法，包括以下步骤：
1)在第一金属基板、第二金属基板以及第三金属基板中分别形成多个过孔，所述第一、第二、第三金属基板中的多个过孔呈矩阵排列，过孔的直径为5毫米，相邻过孔之间的间距为5毫米，所述第一、第二、第三金属基板的材质为铜；
2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理，所述干燥处理的温度为80℃以及时间为80秒；
3)在所述第一金属基板的下表面铺设氟树脂外耐候层，在所述第一金属基板的上表面铺设氟树脂-橡胶复合层，接着在所述氟树脂-橡胶复合层上铺设所述第二金属基板，接着在所述第二金属基板的上表面铺设橡胶-EVA复合层，接着在所述橡胶-EVA复合层上铺设所述第三金属基板，接着在所述第三金属基板的上表面铺设EVA层，所述氟树脂外耐候层包括：氟树脂100份，导热纳米颗粒20份，玻璃纤维10份。所述氟树脂-橡胶复合层包括：氟树脂80份，橡胶60份；导热纳米颗粒30份；碳纤20份。所述橡胶-EVA复合层包括：橡胶50份，EVA60份，导热纳米颗粒18份；碳纤维15份。所述EVA层包括：EVA100份，导热绝缘纳米颗粒20份，玻璃纤维15份。；
4)进行热压合处理，热压合处理的具体工艺为：在100℃的温度下，以压力增加速率为每分钟增加1Kg/cm2的条件将压力增至15Kg/cm2，保持20分钟，接着以压力增加速率为每分钟增加6Kg/cm2的条件将压力增至50Kg/cm2，保持20分钟，接着以压力降低速率为4Kg/cm2的条件将压力降至15Kg/cm2，保持10分钟，接着以压力降低速率为2Kg/cm2的条件将压力降为0，然后在60℃的条件下固化90小时,最后冷却至室温，使得所述氟树脂外耐候层、所述氟树脂-橡胶复合层、所述橡胶-EVA复合层以及所述EVA层各自的一部分进入与上述各层分别相邻的金属基板的各个过孔中，上述各树脂层在各过孔中相互粘结在一起，以得到所述太阳能电池背板。
将上述方法制备的太阳能电池背板进行性能测试，结果表明，其与太阳能电池组件EVA胶层的剥离强度为145N/cm，水汽透过率为0.26g/m2*d，导热系数为25.62W/m*k。
以上所述是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也视为本发明的保护范围。

Claims (9)

1.一种太阳能电池背板的制备方法，其特征在于：包括以下步骤：
1)在第一金属基板、第二金属基板以及第三金属基板中分别形成多个过孔；
2)在所述第一、第二、第三金属基板的各自的上表面和下表面分别涂刷粘结剂，并进行干燥处理；
3)在所述第一金属基板的下表面铺设氟树脂外耐候层，在所述第一金属基板的上表面铺设氟树脂-橡胶复合层，接着在所述氟树脂-橡胶复合层上铺设所述第二金属基板，接着在所述第二金属基板的上表面铺设橡胶-EVA复合层，接着在所述橡胶-EVA复合层上铺设所述第三金属基板，接着在所述第三金属基板的上表面铺设EVA层；
4)进行热压合处理，使得所述氟树脂外耐候层、所述氟树脂-橡胶复合层、所述橡胶-EVA复合层以及所述EVA层各自的一部分进入与上述各层分别相邻的金属基板的各个过孔中，以得到所述太阳能电池背板。
2.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述步骤2)中的所述干燥处理的温度为70-120℃以及时间为50-90秒。
3.根据权利要求2所述的太阳能电池背板的制备方法，其特征在于：所述步骤4)中的热压合处理的具体工艺为：在100-120℃的温度下，以压力增加速率为每分钟增加1-3Kg/cm2的条件将压力增至15-20Kg/cm2，保持10-20分钟，接着以压力增加速率为每分钟增加4-6Kg/cm2的条件将压力增至40-50Kg/cm2，保持20-30分钟，接着以压力降低速率为4-6Kg/cm2的条件将压力降至15-20Kg/cm2，保持5-10分钟，接着以压力降低速率为1-2Kg/cm2的条件将压力降为0，然后在50-80℃的条件下固化70-100小时,最后冷却至室温。
4.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述氟树脂外耐候层包括：氟树脂100份，导热纳米颗粒10-20份，玻璃纤维5-10份。
5.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述氟树脂-橡胶复合层包括：氟树脂60-80份，橡胶60-80份；导热纳米颗粒20-30份；碳纤维10-20份。
6.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述橡胶-EVA复合层包括：橡胶50-70份，EVA40-60份，导热纳米颗粒10-20份；碳纤维10-15份。
7.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述EVA层包括：EVA100份，导热绝缘纳米颗粒10-20份，玻璃纤维10-15份。
8.根据权利要求1所述的太阳能电池背板的制备方法，其特征在于：所述第一、第二、第三金属基板中的多个过孔呈矩阵排列，过孔的直径为3-5毫米，相邻过孔之间的间距为5-10毫米。
9.一种太阳能电池背板，其特征在于，采用权利要求1-8任一项所述的方法制备形成的。
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