CN111253876A - 一种光伏组件用封装胶膜及其制备方法 - Google Patents

一种光伏组件用封装胶膜及其制备方法 Download PDF

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CN111253876A
CN111253876A CN202010321618.3A CN202010321618A CN111253876A CN 111253876 A CN111253876 A CN 111253876A CN 202010321618 A CN202010321618 A CN 202010321618A CN 111253876 A CN111253876 A CN 111253876A
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冒艺
季明龙
王强
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Zhongtian Photovoltaic Materials Co ltd
Jiangsu Zhongtian Technology Co Ltd
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Abstract

本发明公开了一种光伏组件用封装胶膜，所述封装胶膜为透明三层结构，中间层为基膜层，基膜层两侧为粘合层，所述基膜层厚度为50‑150um，粘合层厚度为100‑300um，整体胶膜厚度为300‑700um，所述基膜层的配方包括如下重量分组分:高熔点树脂80‑90份,热稳定剂0.1‑0.5份,抗氧剂0.1‑0.5份,光稳定剂0.1‑0.7份,无机添加剂0.2‑10份;所述粘合层的配方包括如下重量分组分:聚合物树脂100份，交联剂0.4‑1.5份，交联助剂0.1‑1.0份，硅烷偶联剂0.1‑1.5份，抑制剂20ppm‑500ppm，光稳定剂0.1‑0.5份，抗氧剂0.1‑1.0份。本发明的目的在于为了克服下层透明封装胶膜的使用无法有效增加电池片对光线的利用率的缺点，采用多层结构设计，既能保证胶膜的透光率，又能提高胶膜对光线的反射率，从而提高电池片对光线的利用率。

Description

一种光伏组件用封装胶膜及其制备方法
技术领域
本发明涉及太阳能电池领域，特别涉及一种光伏组件用封装胶膜及其制备方法。
背景技术
传统的晶硅太阳能组件结构为光伏玻璃/光伏组件封装胶膜/晶硅电池片/光伏组件封装胶膜/背板的五层结构。随着市场发展，目前兴起双玻组件，其结构为光伏玻璃/封装胶膜/晶硅电池片/封装胶膜/光伏玻璃，采用玻璃替代背板结构，有利于双面发电组件，提高背面发电效率。
目前双玻组件中下层透明封装胶膜按种类划分为高透型和高截止型封装胶膜。高截止型的封装胶膜的使用使得290-380nm波段的紫外光线被截止，电池片无法有效利用到该波段的光线。而高透型的封装胶膜虽然可以保证290-1100nm波段光的穿透性，但电池片与电池片间的间隙部分光线直接穿透，无法通过反射或漫反射等作用到电池片表面，增加了光线损耗，无法有效提高电池片对光线的利用率。
发明内容
本发明的目的是提供一种光伏组件用封装胶膜及其制备方法。
本发明的上述技术目的是通过以下技术方案得以实现的：
优选的，所述封装胶膜为透明三层结构，中间层为基膜层，基膜层两侧为粘合层，所述基膜层厚度为50-150um，粘合层厚度为100-300um，整体胶膜厚度为300-700um，所述基膜层的配方包括如下重量分组分:高熔点树脂80-90份,热稳定剂0.1-0.5份,抗氧剂0.1-0.5份,光稳定剂0.1-0.7份,无机添加剂 0.2-10份;
所述粘合层的配方包括如下重量分组分:聚合物树脂100份，交联剂0.4-1.5份
交联助剂0.1-1.0份，硅烷偶联剂0.1-1.5份，抑制剂20ppm-500ppm，光稳定剂0.1-0.5份，抗氧剂0.1-1.0份。
优选的，所述基膜层中高熔点树脂为聚乙烯、聚丙烯、乙烯-a烯烃共聚物、接枝改性聚乙烯、接枝改性聚丙烯等熔点在150℃以上聚合物材料中的一种或多种的组合；
所述热稳定剂为三乙基磷酸酯、亚磷酸三苯酯中的一种或多种的组合；
所述抗氧化剂为抗氧化剂1010、硫代二丙酸二月桂酯、季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯中的一种或多种的组合；
所述光稳定剂为2,2,6,6-四甲基-4-哌啶基硬脂酸酯、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯、双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯中的一种或多种的组合；
所述无机添加剂为二氧化硅、滑石粉、云母粉、硫酸钡、高岭土中的一种或多种的组合。
优选的，所述高熔点数值的折射率为1.5-2.0。
优选的，所述聚合物树脂为聚乙烯、聚醋酸乙烯酯、乙烯-a烯烃共聚物中的一种或多种的组合；
所述交联剂为1，1-二叔丁基过氧化-3，3，5-三甲基环己烷、1，1-二叔丁基过氧化环己烷、叔丁基过氧化碳酸异丙酯、叔丁基过氧化-3，5，5-三甲基己酯、叔丁基过氧化碳酸-2-乙基己酯中的一种或多种的组合；
所述交联助剂为乙二胺四亚甲基膦酸、二季戊四醇五丙烯酸酯、二苯甲酰苯醌二肟、甲基丙烯酸甲酯、二甲基丙烯酸乙二醇酯、双甲基丙烯酸二缩三乙二醇酯、邻苯二甲酸二烯丙酯、三烯丙基氰尿酸酯中的一种或多种的组合；
所述硅烷偶联剂为γ-氨丙基三乙氧基硅烷、γ-缩水甘油醚氧丙基三甲氧基硅烷、γ-（甲基丙烯酰氧）丙基三甲氧基硅烷、N-（β-氨乙基）-γ氨丙基三甲（乙）氧基硅烷、乙烯基乙氧基硅烷、硅烷低聚物中的一种或多种的组合；
所述抑制剂为对苯二酚、叔丁基邻苯二酚、对苯酚单丁醚中的一种或多种组合；
所述光稳定剂为2,2,6,6-四甲基-4-哌啶基硬脂酸酯、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯、双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯中的一种或多种的组合；
所述抗氧剂为抗氧化剂1010、硫代二丙酸二月桂酯、季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯中的一种或多种的组合。
优选的，所述聚合物树脂的折射率为1.4-1.5。
优选的，所述基膜层表面设有锥形压花结构。
一种光伏组件用封装胶膜的制备方法，其特征在于：包括如下步骤：
（1）基膜层的制备：将高熔点树脂在真空转鼓中70-90℃下干燥3.5-4.5小时，再按配方比加入热稳定剂、抗氧剂、光稳定剂和无机添加剂进行混合，将混合后的粒子加入挤出机中挤出熔融，从进料口进入到模具内，然后经过流延机头的模唇挤出成型，再经过冷却辊冷却后收卷，即可得到目标基膜层；
（2）粘合层的制备：将聚合物树脂、交联剂、交联助剂、硅烷偶联剂、抑制剂、光稳定剂、抗氧剂按照配方比添加到高速混料机中进行预混合，混合温度35-45℃，混合时间1-3h，即可得到目标粘合层组分；
（3）封装胶膜的制备：然后在80-100℃温度下通过淋膜机将粘合层组分淋到基膜层表面，冷却收卷即可得到目标光伏组件用封装胶膜。
综上所述，本发明的有益效果为：通过对中间基膜层表面结构的设计，及三层结构间折射率的差异来影响光的折射和反射，使得这种三层结构的封装胶膜既能保证从组件正面穿透的光线能经过反射传输到电池片表面，减少光线损耗，又能保证组件背面反射的光线能穿透胶膜应用在双面发电领域。有效提升了组件对光线的利用效率，提升组件的输出功率，提高组件发电增益效果。
具体实施方式
下面结对本发明的具体实施方式作进一步说明，本实施例不构成对本发明的限制。
所述封装胶膜为透明三层结构，中间层为基膜层，基膜层两侧为粘合层，所述基膜层厚度为50-150um，粘合层厚度为100-300um，整体胶膜厚度为300-700um，所述基膜层表面设有锥形压花结构。
实施例1
取75份聚丙烯树脂和10份乙烯-辛烯共聚物在真空转鼓中80℃下干燥4小时，再加入0.1份三乙基磷酸酯、0.1份亚磷酸三苯酯、0.3份抗氧化剂1010、0.2份双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯和2份二氧化硅、3份滑石粉、1份云母粉进行混合，将混合后的粒子加入挤出机中挤出熔融，然后经过流延机头的模唇挤出成型，再经过冷却辊冷却后收卷，即可得到基膜层。
取95份乙烯-辛烯共聚物、5份聚乙烯、0.8份叔丁基过氧化碳酸异丙酯、0.2份邻苯二甲酸二烯丙酯、0.5份γ-（甲基丙烯酰氧）丙基三甲氧基硅烷、0.2份硅烷低聚物、100ppm叔丁基邻苯二酚、0.2份双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯和0.3份抗氧化剂1010，加入高速混料机中进行预混合，混合温度40℃，混合时间2h，然后在100℃温度下通过淋膜机将粘合层组分淋到基膜层表面，冷却收卷即可得到目标光伏组件用封装胶膜。
实施例2
取70份聚丙烯树脂和15份接枝改性聚乙烯在真空转鼓中85℃下干燥3.5小时，再加入0.3份亚磷酸三苯酯、0.4份硫代二丙酸二月桂酯、0.3份双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯和3份硫酸钡、2份滑石粉、2份云母粉进行混合，将混合后的粒子加入挤出机中挤出熔融，然后经过流延机头的模唇挤出成型，再经过冷却辊冷却后收卷，即可得到基膜层。
取95份聚醋酸乙烯酯、5份聚乙烯、0.8份叔丁基过氧化-3，5，5-三甲基己酯、0.5份乙二胺四亚甲基膦酸、1份γ-氨丙基三乙氧基硅烷、200ppm对苯二酚、0.3份聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯和0.5份硫代二丙酸二月桂酯，加入高速混料机中进行预混合，混合温度45℃，混合时间1h，然后在90℃温度下通过淋膜机将粘合层组分淋到基膜层表面，冷却收卷即可得到目标光伏组件用封装胶膜。
实施例3
取75份聚丙烯树脂和10份乙烯-辛烯共聚物在真空转鼓中90℃下干燥3.5小时，再加入0.4份三乙基磷酸酯、0.2份亚磷酸三苯酯、0.4份季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯、0.6份聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯和2份二氧化硅、2份高岭土、4份硫酸钡进行混合，将混合后的粒子加入挤出机中挤出熔融，然后经过流延机头的模唇挤出成型，再经过冷却辊冷却后收卷，即可得到基膜层。
取90份乙烯-辛烯共聚物、10份聚醋酸乙烯酯、1份叔丁基过氧化-3，5，5-三甲基己酯、0.8份三烯丙基氰尿酸酯、1份乙烯基乙氧基硅烷、0.3份硅烷低聚物、300ppm对苯酚单丁醚、0.4份聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯和0.6份季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯，加入高速混料机中进行预混合，混合温度35℃，混合时间3h，然后在90℃温度下通过淋膜机将粘合层组分淋到基膜层表面，冷却收卷即可得到目标光伏组件用封装胶膜。
本发明的目的是为了克服下层透明封装胶膜的使用无法有效增加电池片对光线的利用率的缺点，采用多层结构设计，既能保证胶膜的透光率，又能提高胶膜对光线的反射率，从而提高电池片对光线的利用率。
以上所述，仅是本发明的较佳实施例而已，不用于限制本发明，本领域技术人员可以在本发明的实质和保护范围内，对本发明做出各种修改或等同替换，这种修改或等同替换也应视为落在本发明技术方案的保护范围内。

Claims (7)

1.一种光伏组件用封装胶膜，其特征在于，所述封装胶膜为透明三层结构，中间层为基膜层，基膜层两侧为粘合层，所述基膜层厚度为50-150um，粘合层厚度为100-300um，整体胶膜厚度为300-700um，所述基膜层的配方包括如下重量分组分:高熔点树脂80-90份,热稳定剂0.1-0.5份,抗氧剂0.1-0.5份,光稳定剂0.1-0.7份,无机添加剂 0.2-10份;
所述粘合层的配方包括如下重量分组分:聚合物树脂100份，交联剂0.4-1.5份，交联助剂0.1-1.0份，硅烷偶联剂0.1-1.5份，抑制剂20ppm-500ppm，光稳定剂0.1-0.5份，抗氧剂0.1-1.0份。
2.根据权利要求1所述的一种光伏组件用封装胶膜，其特征在于：所述基膜层中高熔点树脂为聚乙烯、聚丙烯、乙烯-a烯烃共聚物、接枝改性聚乙烯、接枝改性聚丙烯等熔点在150℃以上聚合物材料中的一种或多种的组合；
所述热稳定剂为三乙基磷酸酯、亚磷酸三苯酯中的一种或多种的组合；
所述抗氧化剂为抗氧化剂1010、硫代二丙酸二月桂酯、季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯中的一种或多种的组合；
所述光稳定剂为2,2,6,6-四甲基-4-哌啶基硬脂酸酯、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯、双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯中的一种或多种的组合；
所述无机添加剂为二氧化硅、滑石粉、云母粉、硫酸钡、高岭土中的一种或多种的组合。
3.根据权利要求2所述的一种光伏组件用封装胶膜，其特征在于：所述高熔点数值的折射率为1.5-2.0。
4.根据权利要求1所述的一种光伏组件用封装胶膜，其特征在于：所述聚合物树脂为聚乙烯、聚醋酸乙烯酯、乙烯-a烯烃共聚物中的一种或多种的组合；
所述交联剂为1，1-二叔丁基过氧化-3，3，5-三甲基环己烷、1，1-二叔丁基过氧化环己烷、叔丁基过氧化碳酸异丙酯、叔丁基过氧化-3，5，5-三甲基己酯、叔丁基过氧化碳酸-2-乙基己酯中的一种或多种的组合；
所述交联助剂为乙二胺四亚甲基膦酸、二季戊四醇五丙烯酸酯、二苯甲酰苯醌二肟、甲基丙烯酸甲酯、二甲基丙烯酸乙二醇酯、双甲基丙烯酸二缩三乙二醇酯、邻苯二甲酸二烯丙酯、三烯丙基氰尿酸酯中的一种或多种的组合；
所述硅烷偶联剂为γ-氨丙基三乙氧基硅烷、γ-缩水甘油醚氧丙基三甲氧基硅烷、γ-（甲基丙烯酰氧）丙基三甲氧基硅烷、N-（β-氨乙基）-γ氨丙基三甲（乙）氧基硅烷、乙烯基乙氧基硅烷、硅烷低聚物中的一种或多种的组合；
所述抑制剂为对苯二酚、叔丁基邻苯二酚、对苯酚单丁醚中的一种或多种组合；
所述光稳定剂为2,2,6,6-四甲基-4-哌啶基硬脂酸酯、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、聚丁二酸(4-羟基-2,2,6,6-四甲基-1-哌啶乙醇)酯、双(1，2，2，6，6-五甲基-4-哌啶基)癸二酸酯中的一种或多种的组合；
所述抗氧剂为抗氧化剂1010、硫代二丙酸二月桂酯、季戊四醇四(双-T-丁基羟基氢化肉桂酸)酯中的一种或多种的组合。
5.根据权利要求4所述的一种光伏组件用封装胶膜，其特征在于：所述聚合物树脂的折射率为1.4-1.5。
6.根据权利要求1所述的一种光伏组件用封装胶膜，其特征在于：所述基膜层表面设有锥形压花结构。
7.一种光伏组件用封装胶膜的制备方法，其特征在于：包括如下步骤：
基膜层的制备：将高熔点树脂在真空转鼓中70-90℃下干燥3.5-4.5小时，再按配方比加入热稳定剂、抗氧剂、光稳定剂和无机添加剂进行混合，将混合后的粒子加入挤出机中挤出熔融，从进料口进入到模具内，然后经过流延机头的模唇挤出成型，再经过冷却辊冷却后收卷，即可得到目标基膜层；
粘合层的制备：将聚合物树脂、交联剂、交联助剂、硅烷偶联剂、抑制剂、光稳定剂、抗氧剂按照配方比添加到高速混料机中进行预混合，混合温度35-45℃，混合时间1-3h，即可得到目标粘合层组分；
封装胶膜的制备：然后在80-100℃温度下通过淋膜机将粘合层组分淋到基膜层表面，冷却收卷即可得到目标光伏组件用封装胶膜。
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Application publication date: 20200609