CN109087962B - Packaging front plate and preparation process thereof - Google Patents
Packaging front plate and preparation process thereof Download PDFInfo
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- CN109087962B CN109087962B CN201811118206.9A CN201811118206A CN109087962B CN 109087962 B CN109087962 B CN 109087962B CN 201811118206 A CN201811118206 A CN 201811118206A CN 109087962 B CN109087962 B CN 109087962B
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- CXQXSVUQTKDNFP-UHFFFAOYSA-N octamethyltrisiloxane Chemical compound C[Si](C)(C)O[Si](C)(C)O[Si](C)(C)C CXQXSVUQTKDNFP-UHFFFAOYSA-N 0.000 description 5
- UGFMBZYKVQSQFX-UHFFFAOYSA-N para-methoxy-n-methylamphetamine Chemical compound CNC(C)CC1=CC=C(OC)C=C1 UGFMBZYKVQSQFX-UHFFFAOYSA-N 0.000 description 5
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- BHKKSKOHRFHHIN-MRVPVSSYSA-N 1-[[2-[(1R)-1-aminoethyl]-4-chlorophenyl]methyl]-2-sulfanylidene-5H-pyrrolo[3,2-d]pyrimidin-4-one Chemical compound N[C@H](C)C1=C(CN2C(NC(C3=C2C=CN3)=O)=S)C=CC(=C1)Cl BHKKSKOHRFHHIN-MRVPVSSYSA-N 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Abstract
The invention provides a packaging front plate and a preparation process thereof, wherein the packaging front plate is a composite film attached to the upper surface of a solar cell module. The packaging front plate can meet the requirements of lower water vapor transmittance and lower service life requirements (less than five years) of mobile energy sources, and meanwhile, the surface of the flexible front plate is fingerprint-proof and scratch-resistant, the packaging process is simple and efficient, and the material and process cost is lower; the packaging front plate is lighter in weight, thinner in thickness, softer than the traditional front plate, lower in material cost and simple in process.
Description
Technical Field
The invention relates to a solar cell packaging assembly, in particular to a packaging front plate applied to the field of flexible mobile solar cells and a preparation process thereof.
Background
At present, in a solar cell module, packaging quality plays an important role in the service life of a cell. The front plate sealing structure of the solar cell module is mainly used for isolating air and water vapor from penetrating into the cell module, and plays a role in protecting the solar cell. The packaging material generally uses an adhesive film mainly comprising PVB and EVA, and has the functions of fixing the battery piece and isolating air and water vapor so as to ensure that the battery has longer service life after being packaged. The PVB and EVA materials have insufficient comprehensive performance in the sealing of the solar cell, the water blocking performance is not good enough, and after a certain time, water vapor can enter the inside of the cell assembly along the edge of the cell assembly; meanwhile, the bonding strength with metal is not high enough, so that after the solar battery pack is used for a certain time, the electrode is separated from the adhesive film, and the packaging effect is lost.
Aiming at the defect of the sealing performance of the traditional solar cell packaging front plate material, patent CN102738283A discloses a front plate packaging structure of a solar module, wherein the packaging front plate structure is arranged on a first EVA film, and a layer of ETFE fluoroplastic film is used, so that the structure can improve the durability and the heat insulation performance. As a new variety of solar cells, flexible thin film solar cells are becoming more and more important, with advanced technology, excellent performance and wide application. The part of flexible packaging front plate adopts fluorine film type material, and ageing resistance is higher, and outdoor service life can reach more than 25 years, but fluorine film price is expensive, and adopts traditional encapsulation glued membrane to seal the technology complicacy, and the yields is lower, and the product is thick again hard after the encapsulation, and weight is heavier, does not satisfy consumer goods removal energy class lightweight requirement.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention particularly provides a high-light-source packaging front plate structure and a preparation method thereof. The invention develops a packaging front plate material and discloses a preparation process thereof, wherein the packaging front plate of the solar battery can be applied to meet the requirements of fingerprint resistance, scratch resistance, lower water vapor transmittance and lower service life of mobile energy sources of less than 5 years, and meanwhile, the front plate is lighter in weight and thinner in thickness, is softer than the traditional front plate, is lower in material cost and simple in process, and really meets the requirements of light weight and softening of power generation paper.
The invention provides a packaging front plate, which is a composite film attached to the upper surface of a solar cell module and is characterized by comprising a release coating, a frosted aging-resistant layer, a first film substrate layer, a first adhesive layer and a water vapor barrier layer from top to bottom.
The term "packaging front plate" used in the present invention refers to a material that plays a role in packaging protection on the upper surface of a photovoltaic chip. The packaging front plate is actually a composite film covered on the upper surface of the battery component, the film has a multi-layer structure, and is composed of a plurality of material layers with the same or different properties and compositions, and each material layer can be compounded together through the technical means of deposition, film plating, lamination and the like through the structural forms of coating and films, so that the packaging front plate is formed. The packaging front plate materials commonly used in the prior art are polymers such as PVB polyvinyl butyral resin, EVA ethylene-vinyl acetate copolymer and the like.
The packaging front plate in the prior art has single composition, basically one or two layers of PVB, EVA, PET or ETFE films are covered on the upper surface of the battery component, the degree of recombination is low, the functions are limited, and the balance of the comprehensive properties of the packaging front plate among the performances of water vapor resistance, light transmittance, chemical stability and the like can not be met; and the preparation process of the packaging front plate film in the prior art is complex, the requirement on equipment is high, and the cost of film composition materials is high. Meanwhile, in the prior art, part of flexible packaging front plates are laminated by adopting fluorine film materials and packaging adhesive films, although the fluorine film has higher ageing resistance and the outdoor service life can reach more than 25 years, the fluorine film has high price, the traditional packaging adhesive film is adopted for packaging, the process is complex, the yield is lower, the product is thick and hard after being packaged, the weight is heavier, and the requirement of movable energy light weight of consumer products is not met.
The mobile solar cell packaging front plate provided by the invention has the following performance comprehensive indexes: the thickness is 0.1-0.4mm, the light transmittance is more than 90%, the water vapor transmittance is 10-2g/m2day and 10-6g/m2day, the surface hardness is 2H-3H, the tensile strength is more than 170MPa, and the elongation at break is more than 140%. The packaging front plate has the advantages that the performances in the aspects of water resistance, light transmittance, weather resistance, insulativity, wear resistance and the like are improved compared with the prior art.
The packaging front plate composite film provided by the invention eliminates a fluorine-containing film with high cost and complex process, and meets the packaging standard of a high-light-transmission mobile battery plate by using a composite layer film composed of organic and/or inorganic materials.
In a further preferred scheme, the lower surface of the water vapor barrier layer further comprises a modified primer coating layer, so that the weather resistance of the packaging front plate can be improved.
In a further preferred embodiment, the modified basecoat lower surface further comprises a second film substrate layer. In a further preferred embodiment, the lower surface of the second film substrate layer further includes a second adhesive layer, so as to enhance light transmittance.
In a further preferred embodiment, the lower surface of the second adhesive layer further includes a PE protective film. In a further preferred embodiment, the release coating has a thickness of 1-10um.
In a further preferred embodiment, the matte anti-aging layer has a thickness of 1-10um.
In a further preferred embodiment, the abrasive aging resistant layer contains abrasive particles, which are organic particles, inorganic particles, or a combination of both.
In a further preferred embodiment, the organic particles are PMMA, PBMA, PDMS and the inorganic particles are SiO2, al2O3, zrO2.
In a further preferred embodiment, the first film substrate layer has a thickness of 50 to 200um.
In a further preferred embodiment, the first film base material layer is a PET film with high light transmittance, and the light transmittance is more than 90%.
In a further preferred embodiment, the first and second adhesive layers have a light transmittance of 90% or more and a thickness of 5 to 30um.
In a further preferred embodiment, the water vapor barrier layer has a thickness of 1-30um.
In a further preferred embodiment, the modified primer coating has a thickness of 1 to 15um, and is optionally an acrylic, polyurethane or polyester-based coating.
In a further preferred scheme, the second film substrate layer is a PET, PEN or PBT film with high light transmittance, the light transmittance is more than 90%, and the thickness is 50-200um.
The invention further provides a preparation process of the packaging front plate, which is characterized by comprising the following steps of:
step 1: uniformly mixing the frosted particles, the anti-aging agent and the organic polymer solution, and forming a dry film of a continuous frosted anti-aging layer on the upper surface of the first film substrate layer through treatment;
step 2: preparing a dry film of the anti-sticking coating on the upper surface of the dry film by adopting the composite film prepared in the step 1;
step 3: preparing a fluid of a first adhesive layer, adopting the composite film prepared in the step 2, and treating the fluid on the lower surface of a first film substrate layer in a wire coating, knife coating or roller coating mode to obtain a wet film of the first adhesive layer, and drying at 50-100 ℃ for 1-5min to obtain a dry film of the first adhesive layer, wherein the thickness of the dry film is 5-30 mu m;
step 4: and (3) adopting the composite film prepared in the step (3), and preparing a water vapor barrier layer on the lower surface of the first adhesive layer by adopting an atomic layer deposition process or a magnetron sputtering process.
In a further preferred embodiment, the method further comprises the steps of: and the lower surface of the water vapor barrier layer is coated with a wet film of the modified primer coating, and a dry film of the modified primer coating is formed after the wet film is dried at a high temperature of 70-90 ℃.
In a further preferred embodiment, the method further comprises the steps of: and the lower surface of the dry film of the modified prime coating is compounded with a second film substrate layer.
Alternatively, the invention also provides another preparation process of the packaging front plate, which is characterized by further comprising the following steps:
step 1: uniformly mixing the frosted particles, the anti-aging agent and the organic polymer solution, and forming a dry film of a continuous frosted anti-aging layer on the upper surface of the first film substrate layer through treatment;
step 2: preparing a dry film of the anti-sticking coating on the upper surface of the dry film by adopting the composite film prepared in the step 1;
step 3: preparing a fluid of a first adhesive layer, adopting the composite film prepared in the step 2, treating the fluid on the lower surface of a first film substrate layer in a wire coating, knife coating or roller coating mode to obtain a wet film of the first adhesive layer, and drying at 50-100 ℃ for 1-5min to obtain a dry film of the first adhesive layer;
step 4: providing a second film substrate layer, coating a wet film of the modified primer coating on the upper surface of the second film substrate layer, and drying the wet film at a high temperature of 70-90 ℃ to form a dry film of the modified primer coating; then, preparing a water vapor barrier layer on the upper surface of the modified base coat by adopting an atomic layer deposition process or a magnetron sputtering process; and then sequentially combining the composite film prepared in the step with the composite film prepared in the step 3 in a lamination manner, and rolling for standby after pressurizing, bonding and compounding, wherein the water vapor barrier layer is bonded with the first adhesive layer.
In a further preferred scheme, a wet film of the second adhesive layer is prepared on the lower surface of the second film substrate layer by adopting modes of spraying, knife coating or roller coating and the like, and the second adhesive layer is obtained after drying at 50-100 ℃ for 1-5min, wherein the thickness of the second adhesive layer is 5-30 mu m.
In a further preferred embodiment, the method further comprises the steps of: and compounding a PE protective film on the lower surface of the second adhesive layer, and rolling.
In a further preferred embodiment, in the step 1, the specific step of forming the dry film of the frosted aging-resistant layer is: preparing a frosted coating wet film on the upper surface of the film substrate layer in a knife coating or roller coating mode, and curing the wet film at the temperature of 50-100 ℃ after UV irradiation for 10-50S to form a dry film of the continuous frosted aging-resistant layer.
In a further preferred embodiment, in the step 1, the frosted aging resistant layer contains frosted particles, and the frosted particles are organic particles, inorganic particles or a combination of the two; preferably, the organic particles are PMMA, PBMA, PDMS, and the inorganic particles are SiO2, al2O3, zrO2. More preferably, in the step 1, the organic polymer solution is one or two of acrylic materials and polyurethane materials.
In a further preferred embodiment, the modified primer coating may be an acrylic, polyurethane, polyester, or the like coating.
In a further preferred embodiment, in the step 2, the specific preparation steps of the dry film of the coating layer are as follows: and (2) coating a silicone oil solution on the upper surface of the dry film in the step (2) in a blade coating or wire coating mode, and drying at a high temperature of 140-160 ℃ for 1-5min in a hot oven to prepare the dry film of the anti-sticking coating.
In a further preferred embodiment, in the step 3, the preparation process of the fluid of the first adhesive layer includes: adding high polymer resin, tackifying resin, plasticizer, solvent and the like into a reaction kettle, stirring at a high speed of a stirrer for 2000 revolutions per minute, uniformly mixing, and adding the mixed solution into a liquid storage tank of coating equipment; preferably, the polymer resin may be polyurethane or acrylic material.
The packaging front plate and the preparation process thereof provided by the invention can obtain one or more of the following beneficial effects, without limitation, which are superior to those of the related art:
1. the wet film material formed by the frosted particles and the anti-aging agent in the compatible polymer solution is cured to form a film under UV radiation, so that the frosted anti-aging coating is uniformly covered on the high-light-transmission film substrate, the water vapor barrier layer and the battery component at the lower part of the composite film are protected, and the wear resistance, scratch resistance and aging resistance of the front plate are improved;
2. the surface layer of the composite film is baked and solidified by adopting silicone oil solution to form an anti-sticking coating, the process steps are simple, the coating is compact, and anti-sticking and self-cleaning are realized;
3. the water vapor barrier layer can enable the water vapor transmittance to reach the level of 10-5g/m < 2 >/day; the high light-transmitting adhesive layer is introduced to make the flexible front plate light, thin and soft;
4. the traditional method for preparing the composite film layer by layer according to the sequence is abandoned, the invention adopts the film layers with a plurality of layers, and finally, the high-light-transmission adhesive layer is used as the bonding transition layer, and the film layers which are compounded in advance are compounded in sequence; the adhesion strength can be improved by adding tackifying resin into the high-light-transmittance adhesive layer;
5. the flexible front plate packaging component composed of the composite film has the advantages of tight adhesion among the films, high composite degree, excellent comprehensive performance, fingerprint resistance, scratch resistance, lower water vapor transmittance, stable property, low cost, simple and efficient packaging process and higher yield, and meets the service life requirements of consumer mobile energy.
Drawings
Fig. 1 is a schematic structural diagram of a composite film of a package front plate according to an embodiment of the present invention.
Fig. 2 is a schematic structural diagram of a composite film of a package front plate according to an embodiment of the present invention.
Fig. 3 is a schematic structural diagram of a composite film of a package front plate according to an embodiment of the present invention.
Wherein the reference numerals are as follows: 1-anti-sticking coating, 2-frosted anti-aging layer, 3-first film substrate layer, 4-first adhesive layer, 5-water vapor barrier layer, 6-modified base coat, 7-second film substrate layer, 8-second adhesive layer and 9-PE protective film.
Detailed Description
The technical scheme and advantages of the present invention will be explained and illustrated in more detail below with reference to the drawings and detailed description. It should be understood that the matters presented in the description, the detailed description and the accompanying drawings are only for the purpose of clearly illustrating the technical solution of the present invention and its advantages, and are not to be construed as limiting the scope of the present invention. Based on the disclosure of the specification, a person skilled in the art can obtain various changed technical schemes for various reasonable changes, so long as the spirit of the invention is not deviated, and various changed technical schemes are included in the protection scope of the invention.
Example 1
The package front plate of the embodiment is composed of a composite film tightly covered on the upper surface of the solar cell module, and is formed by compounding multiple layers of films. Wherein 1 is an anti-sticking coating, the thickness is preferably 1-10um, more preferably 3-8um, more preferably 5um, and the anti-sticking coating is distributed on the upper surface of the packaging front plate composite film, and has anti-sticking, dustproof and self-cleaning effects; 2 is a frosted anti-aging coating, preferably 1-10um, more preferably 3-8um, more preferably 5um, the specific composition of the layer preferably contains organic or inorganic frosted particles, for example, PMMA, PBMA, PDMS is selected from organic particles, the inorganic particles are SiO2, al2O3 and ZrO2, more preferably contains an anti-aging agent, and the layer has the functions of wear resistance, scratch resistance and aging resistance; 3 is a first film substrate layer, the thickness is preferably 50-200um, more preferably 80-150um, more preferably 100-120um, the first film substrate is preferably a high light-transmitting PET film, the visible light transmittance is more than 90%, and the layer has high light transmittance; 4 is a first adhesive layer, preferably having a light transmittance of 95% or more, a thickness of 100 to 300um, preferably 50 to 200um, more preferably 80 to 150um, still more preferably 100 to 120um, the layer having high light transmittance and light, thin and soft properties; 5 is a water vapor barrier layer with a thickness of 1-30um, more preferably 5-25um, more preferably 10-20um, more preferably 15um, which has the function of blocking water vapor.
The package front plate composite film obtained by the above structure arrangement is shown in fig. 1.
The preparation process of the packaging front plate shown in the structure of fig. 1 comprises the following steps:
step 1: mixing the frosted particles, an anti-aging agent and an organic polymer solution, stirring at a high speed stirrer at 2000 rpm, preparing a frosted coating wet film on the upper surface of the first film substrate layer 3 with the light transmittance of more than 90% in a common coating mode such as knife coating, roller coating and the like, and curing the wet film after 10-50S of UV irradiation at 50-100 ℃ to form a continuous frosted coating dry film, namely a layer 2 in FIG. 1, wherein the frosted particles can be organic particles such as PMMA, PBMA, PDMS or inorganic particles such as SiO2, al2O3 and ZrO2, and the organic polymer solution is one or two of materials such as acrylic acid, polyurethane and the like;
step 2: and (2) coating a silicone oil solution on the upper surface of the film layer 2 by adopting the composite film prepared in the step (1) through a doctor blade coating method, a wire coating method and the like, and drying at a high temperature of 140-160 ℃ for 1-5min through a hot oven to prepare an anti-sticking dry film, namely the layer 1 in the figure 1.
Step 3: preparing a fluid of a first adhesive layer, adopting the composite film prepared in the step 2, and treating the fluid on the lower surface of a first film substrate layer 3 in a wire coating, knife coating or roller coating mode to obtain a wet film of a first adhesive layer 4, and drying at 50-100 ℃ for 1-5min to obtain a dry film of the first adhesive layer, wherein the thickness of the dry film is 5-30 mu m; preferably, the preparation process of the fluid of the first adhesive layer 4 includes: adding high polymer resin, tackifying resin, plasticizer, solvent and the like into a reaction kettle, stirring at a high speed of a stirrer for 2000 revolutions per minute, uniformly mixing, and adding the mixed solution into a liquid storage tank of coating equipment; preferably, the polymer resin may be polyurethane or acrylic material.
Step 4: and (3) adopting the composite film prepared in the step (3), and preparing a water vapor barrier layer on the lower surface of the first adhesive layer (4) by adopting an atomic layer deposition process or a magnetron sputtering process.
The packaging front plate of the embodiment comprises an anti-sticking coating layer 1, a frosted aging-resistant layer 2, a first film substrate layer 3, a first adhesive layer 4 and a water vapor barrier layer 5 which are compounded together.
The frosted anti-aging and anti-sticking coating is prepared on the high light-transmitting film substrate, so that the front plate material is wear-resistant, scratch-resistant, self-cleaning and anti-aging; the water vapor barrier layer is prepared on the high-light-transmittance film substrate, so that the water vapor transmittance can reach the level of 10-5g/m2 day; the flexible front plate has the characteristics of light weight, thinness and softness by introducing the high-light-transmission adhesive layer.
Example 2
In order to further improve the comprehensive performance of the packaging front plate, the packaging front plate composite film can be subjected to the following structural and technological improvements.
Preferably, on the basis of the packaging front plate composite film structure of the embodiment 1, a modified bottom coating 6 is compounded on the lower surface of the water vapor barrier layer 5;
more preferably, a second film substrate layer 7 is laminated to the lower surface of layer 6.
A schematic structure of the package front plate obtained in this embodiment is shown in fig. 2.
The water vapor barrier layer is arranged in the middle layer of the packaging front plate composite film, so that on one hand, the water and gas generated by the battery assembly can be prevented from damaging the water vapor barrier layer, and on the other hand, the problems of open circuit and short circuit caused by contact of substances such as EVA and the like with the solar cell panel can be avoided; 6 is a modified base coat layer, preferably 1-15um, more preferably 3-12um, more preferably 5-8um, which has weather resistance; and 7 is a second film substrate layer, wherein the second film substrate layer is preferably a PET, PEN or PBT film with high light transmittance, the light transmittance is more than 90 percent, the thickness is 50-200um, more preferably 80-150um, still more preferably 100-120um, and the layer has high light transmittance.
The specific preparation steps of the packaging front plate composite film of the embodiment 2 are as follows:
the embodiment 1 package front plate composite film is selected, and preferably further comprises the steps of: coating a wet film of the modified bottom coating 6 on the lower surface of the water vapor barrier layer 5, and drying at a high temperature of 70-90 ℃ to form a dry film of the modified bottom coating 6;
more preferably, the method further comprises the following steps: and the lower surface of the dry film of the modified primer coating 6 is compounded with a second film substrate layer 7.
In addition, as an alternative preparation process, the specific preparation process of the packaging front plate composite film in embodiment 2 includes the following steps:
step 1: mixing the frosted particles, an anti-aging agent and an organic polymer solution, stirring at a high speed stirrer at 2000 rpm, preparing a frosted coating wet film on the upper surface of the first film substrate layer 3 with the light transmittance of more than 90% in a common coating mode such as knife coating, roller coating and the like, and curing the wet film after 10-50S of UV irradiation at 50-100 ℃ to form a continuous frosted coating dry film, namely a layer 2 in FIG. 1, wherein the frosted particles can be organic particles such as PMMA, PBMA, PDMS or inorganic particles such as SiO2, al2O3 and ZrO2, and the organic polymer solution is one or two of materials such as acrylic acid, polyurethane and the like;
step 2: coating a silicone oil solution on the upper surface of the film layer 2 by adopting the composite film prepared in the step 1 through a doctor blade coating mode, a wire coating mode and the like, and drying at a high temperature of 140-160 ℃ for 1-5min through a hot oven to prepare an anti-sticking dry film, namely the layer 1 in the figure 1;
step 3: adopting the composite film prepared in the step 2, preparing a wet film of the first adhesive layer 44 on the lower surface of the first film substrate layer 3 in a spraying, knife coating or roller coating mode, and drying at 50-100 ℃ for 1-5min to obtain a first adhesive 4;
step 4: providing a second film substrate layer 7, coating a wet film of the modified primer coating 6 on the upper surface of the second film substrate layer, and drying the wet film at a high temperature of 70-90 ℃ to form a dry film of the modified primer coating 6; then, preparing a water vapor barrier layer 5 on the upper surface of the modified primer coating 6 by adopting an atomic layer deposition process or a magnetron sputtering process; and then sequentially combining the composite film prepared in the step with the composite film prepared in the step 3 in a lamination manner, and rolling for standby after pressurizing, bonding and compounding, wherein the water vapor barrier layer 5 is adhered with the first adhesive layer 4.
A schematic structural diagram of the front plate of the package obtained according to this alternative manufacturing process is also shown in fig. 2.
The packaging front plate of the embodiment comprises an anti-sticking coating 1, a frosted aging-resistant layer 2, a first film substrate layer 3, a first adhesive layer 4, a water vapor barrier layer 5, a modified prime coating 6 and a second film substrate layer 7 which are compounded together.
Example 3
In order to further improve the performances of weather resistance, high light transmittance, convenient use and the like of the packaging front plate, the packaging front plate composite film can be subjected to the following structural and technological improvements.
Preferably, on the basis of the packaging front plate composite film structure of embodiment 2, the lower surface of the second film substrate layer 7 is compounded with a second adhesive layer 8.
More preferably, a PE protective film 9 is laminated on the lower surface of the second adhesive layer 8.
A schematic structure of the package front plate obtained in this embodiment is shown in fig. 3.
Wherein 8 is a second adhesive layer, preferably with a light transmittance of more than 95% and a thickness of 100-300um, which has the functions of adhesion and isolation, and can be tightly adhered to the upper surface of the solar cell panel when the front plate is packaged; and 9 is a PE protective film which is easy to tear and plays a role in protecting the packaging front plate finished product composite film, and when the packaging front plate composite film is required to be packaged on the surface of the solar cell, the protective film is uncovered.
The flexible solar packaging front plate arranged through the composite film structure has obviously improved performances in the aspects of wear resistance, scratch resistance, water resistance, light transmittance, weather resistance and the like.
The specific preparation process of the packaging front plate shown in fig. 3 comprises the following steps:
on the basis of the package front plate of the structure of example 2, the following steps are also preferably performed: and preparing a wet film of the second adhesive layer on the lower surface of the second film substrate layer by adopting modes of spraying, knife coating or roller coating and the like, and drying at 50-100 ℃ for 1-5min to obtain the second adhesive layer with the thickness of 5-30um.
More preferably, the method further comprises the following steps: and compounding a PE protective film on the lower surface of the second adhesive layer, and rolling.
The packaging front plate of the embodiment comprises an anti-sticking coating, a frosted aging-resistant layer, a first film substrate layer, a first adhesive layer, a water vapor barrier layer, a modified prime coating, a second film substrate layer, a second adhesive layer and a PE protective film which are compounded together.
When the packaging front plate prepared by the preparation process is used, and particularly applied to the upper surface of a flexible mobile solar cell module, a conventional packaging method in the prior art can be adopted. For example, a mold matched with the packaged solar cell panel is prepared firstly, a layer of adhesive mold material is sprayed and sintered on the inner surface of the mold, the solar cell panel is placed into a groove of the mold, then the template on which the solar cell panel is placed is covered with the composite film of the front packaging plate provided by the invention (when the composite film is placed, if the composite film of the front packaging plate contains a PE protective film, the PE protective film on the outermost layer of the composite film can be removed firstly), then the composite film is placed into a laminating machine for packaging, and cooling and demoulding are carried out after the composite film is taken out.
The invention is applied to the packaging front plate of the flexible solar cell, has scratch resistance, lower water vapor transmittance, low cost, simple and efficient packaging process and higher yield, and can meet the service life requirement of consumer mobile energy; the flexible front plate is light, thin and soft by introducing the high-light-transmission adhesive layer.
Here, it should be noted that the description of the above technical solution is exemplary, and the present specification may be embodied in different forms and should not be construed as being limited to the technical solution set forth herein. Rather, these descriptions will be provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solution of the invention is limited only by the scope of the claims.
The shapes, dimensions, ratios, angles, and numbers disclosed for describing aspects of the present specification and claims are merely examples, and thus, the present specification and claims are not limited to the details shown. In the following description, a detailed description of related known functions or configurations will be omitted when it may be determined that the emphasis of the present specification and claims is unnecessarily obscured.
Where the terms "comprising," "having," and "including" are used in this specification, there may be another part or parts unless "only" is used, and the terms used may generally be in the singular but may also mean the plural.
It should be noted that although the terms "first," "second," "top," "bottom," "one side," "another side," "one end," "the other end," etc. may be used and used in this specification to describe various components, these components and portions should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, with top and bottom elements, under certain circumstances, also being interchangeable or convertible with one another; the components at one end and the other end may be the same or different in performance from each other.
In addition, when constituting the components, although not explicitly described, it is understood that a certain error region is necessarily included.
In describing positional relationships, for example, when positional sequences are described as "on," "above," "below," and "next," unless words or terms such as "just" or "directly" are used, it is also possible to include cases where there is no contact or contact between them. If a first element is referred to as being "on" a second element, it does not mean that the first element must be located above the second element in the figures. The upper and lower portions of the component will change in response to changes in the angle and orientation of the view. Thus, in the drawings or in actual construction, if it is referred to that a first element is "on" a second element, it can comprise the case that the first element is "under" the second element and the case that the first element is "over" the second element. In describing the time relationship, unless "just" or "direct" is used, a case where there is no discontinuity between steps may be included in describing "after", "subsequent" and "preceding".
The features of the various embodiments of the invention may be combined or spliced with one another, either in part or in whole, and may be implemented in a variety of different configurations as will be well understood by those skilled in the art. Embodiments of the present invention may be performed independently of each other or may be performed together in an interdependent relationship.
Claims (12)
1. The packaging front plate is a composite film attached to the upper surface of the solar cell module, and is characterized by comprising a release coating, a frosted aging-resistant layer, a first film substrate layer, a first adhesive layer and a water vapor barrier layer from top to bottom;
the lower surface of the water vapor barrier layer also comprises a modified prime coating;
the lower surface of the modified prime coat layer also comprises a second film substrate layer;
the lower surface of the second film substrate layer also comprises a second adhesive layer;
the lower surface of the second adhesive layer also comprises a PE protective film;
the first film substrate layer is a PET film with high light transmittance, the thickness is 50-200um, and the light transmittance is more than 90%; the second film substrate layer is a PET, PEN or PBT film with high light transmittance, the light transmittance is more than 90%, and the thickness is 50-200um.
2. A process for manufacturing a front package board according to claim 1, wherein step 1: uniformly mixing the frosted particles, the anti-aging agent and the organic polymer solution, and forming a dry film of a continuous frosted anti-aging layer on the upper surface of the first film substrate layer through treatment; step 2: preparing a dry film of the anti-sticking coating on the upper surface of the dry film by adopting the composite film prepared in the step 1; step 3: preparing fluid of a first adhesive layer, adopting the composite film prepared in the step 2, treating the fluid on the lower surface of a first film substrate layer in a wire coating, knife coating or roller coating mode to obtain a wet film of the first adhesive layer, and drying to obtain a dry film of the first adhesive layer; step 4: and (3) adopting the composite film prepared in the step (3), and preparing a water vapor barrier layer on the lower surface of the first adhesive layer by adopting an atomic layer deposition process or a magnetron sputtering process.
3. The process for manufacturing a front package board according to claim 2, further comprising the steps of: and the lower surface of the water vapor barrier layer is coated with a wet film of the modified primer coating, and a dry film of the modified primer coating is formed after the wet film is dried at a high temperature of 70-90 ℃.
4. A process for manufacturing a front plate for packaging according to claim 3, further comprising the steps of: and the lower surface of the dry film of the modified prime coating is compounded with a second film substrate layer.
5. The process for manufacturing a package front plate according to claim 4, further comprising the steps of: and preparing a wet film of the second adhesive layer on the lower surface of the second film substrate layer by adopting modes of spraying, knife coating or roller coating and the like, and drying at 50-100 ℃ for 1-5min to obtain the second adhesive layer with the thickness of 5-30um.
6. The process for preparing the packaging front plate according to claim 2, wherein in the step 1, the process for forming the frosted aging-resistant layer dry film specifically comprises the following steps: preparing a frosted coating wet film on the upper surface of the first film substrate layer by a knife coating or roller coating mode, and curing the wet film at the temperature of 50-100 ℃ after UV irradiation for 10-50S to form a dry film of the continuous frosted aging-resistant layer.
7. The process for preparing the packaging front plate according to claim 2, wherein in the step 2, the specific preparation steps of the dry film of the coating layer are as follows: and (2) coating a silicone oil solution on the upper surface of the dry film in the step (2) in a blade coating or wire coating mode, and drying at a high temperature of 140-160 ℃ for 1-5min in a hot oven to prepare the dry film of the anti-sticking coating.
8. A process for preparing the front packaging panel according to claim 1, comprising the steps of:
step 1: uniformly mixing the frosted particles, the anti-aging agent and the organic polymer solution, and forming a dry film of a continuous frosted anti-aging layer on the upper surface of the first film substrate layer through treatment;
step 2: preparing a dry film of the anti-sticking coating on the upper surface of the dry film by adopting the composite film prepared in the step 1;
step 3: preparing a fluid of a first adhesive layer, adopting the composite film prepared in the step 2, treating the fluid on the lower surface of a first film substrate layer in a wire coating, knife coating or roller coating mode to obtain a wet film of the first adhesive layer, and drying at 50-100 ℃ for 1-5min to obtain a dry film of the first adhesive layer; step 4: providing a second film substrate layer, coating a wet film of the modified primer coating on the upper surface of the second film substrate layer, and drying the wet film at a high temperature of 70-90 ℃ to form a dry film of the modified primer coating; then, preparing a water vapor barrier layer on the upper surface of the modified base coat by adopting an atomic layer deposition process or a magnetron sputtering process; and then sequentially combining the composite film prepared in the step with the composite film prepared in the step 3 in a lamination manner, and rolling for standby after pressurizing, bonding and compounding, wherein the water vapor barrier layer is bonded with the first adhesive layer.
9. The process for manufacturing a package front plate according to claim 8, further comprising the steps of: and preparing a wet film of the second adhesive layer on the lower surface of the second film substrate layer by adopting modes of spraying, knife coating or roller coating and the like, and drying at 50-100 ℃ for 1-5min to obtain the second adhesive layer with the thickness of 5-30um.
10. The process for manufacturing a package front plate according to claim 9, further comprising the steps of: and compounding a PE protective film on the lower surface of the second adhesive layer, and rolling.
11. The process for preparing the packaging front plate according to claim 8, wherein in the step 1, the process for forming the frosted aging-resistant layer dry film specifically comprises the following steps: preparing a frosted coating wet film on the upper surface of the first film substrate layer by a knife coating or roller coating mode, and curing the wet film at the temperature of 50-100 ℃ after UV irradiation for 10-50S to form a dry film of the continuous frosted aging-resistant layer.
12. The process for preparing the front packaging board according to claim 8, wherein in the step 2, the specific preparation steps of the dry film of the coating layer are as follows: and (2) coating a silicone oil solution on the upper surface of the dry film in the step (2) in a blade coating or wire coating mode, and drying at a high temperature of 140-160 ℃ for 1-5min in a hot oven to prepare the dry film of the anti-sticking coating.
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