CN111690335A - 一种太阳能电池封装用透明背板 - Google Patents
一种太阳能电池封装用透明背板 Download PDFInfo
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Abstract
一种太阳能电池封装用透明背板，包括透明粘结层、基材层、胶粘层和耐候层，所述透明粘结层由耐候树脂与异氰酸酯制成的涂布液涂覆、固化而成，所述涂布液包括A组分和B组分，所述A组分中各组分按质量份数计为：耐候树脂50份‑83份，改性纳米级填料0.5份‑3份，毛面剂1份‑3份，分散剂0.05份‑0.1份，紫外吸收剂0.9份‑2.5份，光稳定剂0.3份‑1.5份，流平剂0.3份‑1份，溶剂20份‑50份，所述B组分为异氰酸酯，所述耐候树脂由氟碳树脂与丙烯酸树脂按(1‑8):1共混组成，所述异氰酸酯与耐候树脂的NCO/OH的当量比为(0.6‑1.2):1。本发明提供的背板具有高透光率、低雾度、高硬度、耐污、抗划伤的性能，同时还兼具优异的耐紫外性能及耐湿热性能。
Description
技术领域
本发明涉及太阳能电池技术领域，特别是一种太阳能电池封装用背板。
背景技术
太阳能电池组件是一种多层材料的层叠结构，从接触太阳光面向下依次为玻璃前板、第一EVA封装层、发电硅片、第二EVA封装层和薄膜背板或玻璃。随着双面电池技术的成熟，双面发电组件备受关注。传统的双面发电组件为双玻组件，由于易碎、重量过大不易安装等原因使双面电池技术应用受到制约。聚合物透明背板，由于具有优异的柔韧性和强度、透光率高、重量轻的优势并且安装和运维简单，最大程度利用现有设备和工艺，确保了高效双面发电，满足屋顶光伏电站的要求，使双面电池技术的应用更宽泛、更有前景。
聚合物透明太阳能电池背板需要具有优异的耐紫外性能，高的可见光透过率，良好的耐划伤性能等。中国专利文献CN104201224A中透明涂层配方中选用纳米级的填料来调节透光率和雾度，但纳米尺寸的粒子易团聚，很难分散均匀，容易造成透明涂层弊病，有脱层失效的风险。中国专利文献CN110157319A使用硅酸酯和硅烷偶联剂在酸催化下制得的硅化合物来提升涂膜硬度，该方法所得硅化合物孔隙率低，不能有效提升背板的透光率。
目前市场上的聚合物透明背板主要有TPC、KPC及CPC等结构，基体材料选用耐热性好的PET为支撑层。由于耐紫外PET的透光率低于90％。与高透光的玻璃相比不具优势。因此，业内普遍将提升聚合物透明背板的透光率及膜层硬度作为研发课题。
发明内容
本发明所要解决的技术问题是克服已有技术之缺陷，提供一种太阳能电池封装用透明背板，通过配方设计，得到高透光率、高硬度的透明太阳能电池背板，且具有优异的耐湿热性能和耐紫外性能。
本发明的所述技术问题是通过下述技术方案解决的：
一种太阳能电池封装用透明背板，所述透明背板包括透明粘结层、基材层和耐候层，所述透明粘结层由耐候树脂与异氰酸酯制成的涂布液涂覆、固化而成，所述涂布液包括A组分和B组分，所述A组分中各原料按质量份数计为：
所述B组分为异氰酸酯，所述耐候树脂由氟碳树脂与丙烯酸树脂按(1-8):1共混组成，所述异氰酸酯与耐候树脂的NCO/OH的当量比为(0.6-1.2):1。
上述透明背板，所述毛面剂为气相二氧化硅、沉淀二氧化硅；所述毛面剂粒径为2μm-6μm，孔隙率为37％—50％。
上述透明背板，所述气相二氧化硅为有机硅表面处理过的二氧化硅。
上述透明背板，所述紫外吸收剂为二苯甲酮类、苯并三唑类或三嗪类化合物。
上述透明背板，所述紫外吸收剂为侧链含羟基、酯基、醚键官能团的二苯甲酮类、苯并三唑类或三嗪类化合物。
上述透明背板，所述异氰酸酯选自甲苯二异氰酸酯三聚体、异佛尔酮二异氰酸酯三聚体、六亚甲基二异氰酸酯三聚体、二苯基甲烷二异氰酸酯三聚体、甲苯二异氰酸酯二聚体、异佛尔酮二异氰酸酯二聚体、六亚甲基二异氰酸酯二聚体或二苯基甲烷二异氰酸酯二聚体中的一种或其混合物。
上述透明背板，所述氟碳树脂选自含羟基或氨基改性的四氟乙烯-乙烯基醚共聚物、四氟乙烯-乙烯基酯共聚物、三氟氯乙烯-乙烯基醚共聚物、三氟氯乙烯-乙烯基酯共聚物、聚氟乙烯(PVF)、聚偏氟乙烯(PVDF)或四氟乙烯-全氟烷基乙烯基醚共聚物(PFA)中的一种或其混合物。
上述透明背板，所述纳米级填料为金红石型钛白粉、氧化锌或氧化铈，粒径为20nm-80nm。
上述透明背板，所述耐候层为透明粘结层、透明PVF膜或透明PVDF膜，厚度为20μm-30μm。
上述透明背板，所述基材层为厚度150μm-300μm的聚酯薄膜；所述聚酯薄膜选自聚对苯二甲酸乙二醇酯(PET)树脂、聚对苯二甲酸丁二醇酯(PBT)树脂或聚对萘二甲酸乙二醇酯(PEN)树脂中的一种。
有益效果
与现有技术相比，本发明通过表面处理的气相二氧化硅能有效提升透明太阳能电池背板的透光率并提升涂层抗划伤性能。本发明通过纳米级无机紫外屏蔽剂与有机紫外吸收剂配合使用，实现长久有效的屏蔽紫外线的效果；通过优选侧链含羟基、酯基、醚键结构的紫外吸收剂，避免助剂在高温下析出。本发明得到的透明背板具有高透光率、低雾度、高硬度、耐污、抗划伤的性能，同时，还兼具优异的耐紫外性能及耐湿热性能。
具体实施方式
本发明通过应用有机硅表面处理的气相二氧化硅于涂层配方中，能显著提透明背板的透光率和涂层硬度。由于气相二氧化硅的比表面积大，孔隙率较高，能降低涂层膜的折光率，进而有助于提升透明背板的透光率，且雾度可控。通过选用有机表面处理的气相二氧化硅，具有易于分散的特点且得到的膜材料表面疏水性能提高，实际应用时透明背板的耐污性能较好。
本发明中的耐候树脂由氟碳树脂与羟基丙烯酸树脂按(1-8):1共混组成；若氟碳树脂含量低于50％，紫外老化后透明背板的黄变大，透明粘结层易粉化；若氟碳树脂含量大于90％，湿热老化后与基材的附着力不佳，易出现透明粘结层脱落的风险。
本发明中所用气相二氧化硅为有机硅表面处理过的二氧化硅，粒径为2-6μm孔隙率为37％—50％；若使用不处理的二氧化硅或粒径低于2μm的气相二氧化硅在涂料中分散性能差，易沉降；若粒径大于6μm，无机粒子对光线的散射作用明显，导致涂层雾度大，涂层透光率提升不明显。
本发明通过应用毛面剂于涂层配方中，由于毛面剂的比表面积大，孔隙率较高，能降低涂层膜的折光率，进而有助于提升透明背板的透光率，且雾度可控，因此能显著提高透明背板的透光率；并且本发明中使用的毛面剂，具有易于分散的特点且得到的膜材料表面疏水性能好，实际应用于透明背板，透明背板的耐污性能好。本发明中改性纳米级填料为金红石型钛白粉、氧化锌、氧化铈等，粒径为20nm-80nm。
本发明中紫外吸收剂为二苯甲酮类、苯并三唑类、三嗪类化合物，优选侧链含羟基、酯基、醚健官能团的二苯甲酮类、苯并三唑类、三嗪类化合物。本发明中改性纳米级填料，也作为无机紫外屏蔽剂使用。通过选用纳米级无机紫外屏蔽剂与有机紫外吸收剂配合使用，实现长久有效的屏蔽紫外线；通过紫外吸收剂的结构，避免助剂在高温下析出。
本发明中所述透明背板耐候层为厚度20μm-30μm的透明粘结层、透明PVF膜和透明PVDF膜。
本发明中所述透明背板基材层为厚度150μm-300μm的聚酯薄膜。所述聚酯薄膜选择聚对苯二甲酸乙二醇酯(PET)树脂、聚对苯二甲酸丁二醇酯(PBT)树脂或聚对萘二甲酸乙二醇酯(PEN)树脂中的一种。
以下结合具体实施例对本发明做进一步详述，但本发明的实施方式并不限于这几个实施例。
实施例1
涂布液配方：取氟碳树脂(GK-570)30g,丙烯酸树脂(海纳HN-2604)10g，乙酸丁酯55g，纳米级填料TiO2(美礼联RCL69)0.9g，气相二氧化硅(OK607)2.4g，分散剂(BYK2155)0.024g，紫外吸收剂(UV-384)1.5g，光稳定剂(Chimassorb 944)0.5g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)4.2g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆30％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为10μm；在PET的另一面复合干厚为25μm的透明PVF，样片经50℃熟化3天后测试性能。
实施例2
涂布液配方：取氟碳树脂(长兴41011)36g，丙烯酸树脂(江苏三木962)4g，乙酸丁酯50g，纳米级填料TiO2(美礼联RCL69)0.1g，气相二氧化硅(OK520)1.2g，分散剂(BYK2155)0.048g，紫外吸收剂(UV-1577)1.92g，光稳定剂(Chimassorb 944)1.2g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3370)10.18g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆25％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为5μm；在PET的另一面复合干厚为25μm的透明PVDF，样片经50℃熟化3天后测试性能。
实施例3
涂布液配方：取氟碳树脂(长兴41011)20g，丙烯酸树脂(长兴73331-S-60)20g，乙酸丁酯25g，纳米级填料TiO2(美礼联RCL69)2.4g，气相二氧化硅(ACEMATT 3600)0.48g，分散剂(BYK2155)0.072g，紫外吸收剂(UV-400)0.48g，光稳定剂(Chimassorb 944)0.14g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3790)6.5g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆40％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为20μm；在PET的另一面复合干厚为25μm的透明涂层(配方粘结层涂布液配方)，样片经50℃熟化3天后测试性能。
实施例4
涂布液配方：取氟碳树脂(长兴41018)30g，丙烯酸树脂(长兴73331-S-60)10g，乙酸丁酯55g，纳米级填料TiO2(美礼联RCL69)0.9g，气相二氧化硅(ACEMATT 3600)1.2g，分散剂(BYK2155)0.048g，紫外吸收剂(UV-1164)1.5g，光稳定剂(Chimassorb 944)0.5g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)3.37g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆30％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为15μm；在PET的另一面复合干厚为25μm的透明PVF，样片经50℃熟化3天后测试性能。
实施例5
涂布液配方：取氟碳树脂(长兴41011)36g，丙烯酸树脂(海纳HN-2604)4g，乙酸丁酯40g，纳米级填料TiO2(美礼联RCL69)0.9g，气相二氧化硅(ACEMATT 3600)2.4g，分散剂(BYK2155)0.072g，紫外吸收剂(UV-400)0.48g，光稳定剂(Chimassorb 944)0.14g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)5.24g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆35％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为13μm；在PET的另一面复合干厚为25μm的透明涂层(配方粘结层涂布液配方)，样片经50℃熟化3天后测试性能。
对比例1
涂布液配方：取氟碳树脂(长兴41011)40g，乙酸丁酯45g，纳米级填料TiO2(美礼联RCL69)0.9g，分散剂(BYK2155)0.072g，紫外吸收剂(UV-400)1.5g，光稳定剂(Chimassorb944)0.5g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)5.16g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆35％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为13μm；在PET的另一面复合干厚为25μm的透明涂层(配方粘结层涂布液配方)，样片经50℃熟化3天后测试性能。
对比例2
涂布液配方：取氟碳树脂(长兴41011)40g，乙酸丁酯45g，沉淀二氧化硅(ED-30)1.2g，分散剂(BYK2155)0.072g，紫外吸收剂(UV-400)1.5g，光稳定剂(Chimassorb 944)0.5g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)5.16g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆35％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为13μm；在PET的另一面复合干厚为25μm的透明涂层(配方粘结层涂布液配方)，样片经50℃熟化3天后测试性能。
对比例3
涂布液配方：取氟碳树脂(长兴41011)36g，丙烯酸树脂(海纳HN-2604)4g，乙酸丁酯45g，气相二氧化硅(OK520)2.4g，分散剂(BYK2155)0.048g，紫外吸收剂(UV-360)1.5g，光稳定剂(Chimassorb 944)0.5g，抗水解剂(StabaxolⅠ型)0.5g，高剪切分散得涂布液A份，加入异氰酸酯(N3390)3.65g，搅拌均匀，得到透明涂布液。
背板的制作方法：在PET的一侧涂覆35％的透明粘结层涂布液，经140℃干燥2min；得到粘结厚度为13μm；在PET的另一面复合干厚为25μm的透明涂层(配方粘结层涂布液配方)，样片经50℃熟化3天后测试性能。
以下给出本发明和对比例的测试结果，见表1，所选用的测试标准和测试结果如下：
1、附着力测试
依据标准GB/T 9286-1998进行测试。
2、透光率测试：
按照GB/T 2410-2008《透明塑料透光率和雾度试验方法》检测；
3、涂层硬度测试：
按照GB/T 6739-1996《涂膜硬度试验方法》检测；
4、紫外阻隔率测试：
按照紫外分光光度计进行测试。
5、与EVA剥离强度测试：
按照GB/T2790-1995《胶黏剂180°剥离强度试验方法与标准》检测。
表1实施例与对比例的各项测试性能对比
从表1可见：对比例1配方中是没有毛面剂及丙烯酸树脂，所得背板透光率低于90％，并且涂层硬度仅为HB，PCT72h后附着力差；对比力2中同样没有丙烯酸树脂，而且使用的是非本专利优选的毛面剂，所得产品雾度大、透光率低，PCT72h后附着力差；而对比例3中是非本专利优选的有机紫外吸收剂，所得涂层80℃高温4d后助剂严重析出使得与EVA的剥离强度偏低。对比例2与对比例3都是仅通过有机紫外吸收剂实现紫外屏蔽，存在紫外120kwh/m2老化后紫外阻隔性衰减较大。从实施例1-5可以看出，使用本发明配方所得太阳能电池背板在许多方面性能表现较好，具有更好的质量。
Claims (10)
1.一种太阳能电池封装用透明背板，其特征在于，所述透明背板包括透明粘结层、基材层和耐候层，所述透明粘结层由耐候树脂与异氰酸酯制成的涂布液涂覆、固化而成，所述涂布液包括A组分和B组分，所述A组分中各原料按质量份数计为：
所述B组分为异氰酸酯，所述耐候树脂由氟碳树脂与丙烯酸树脂按(1-8):1共混组成，所述异氰酸酯与耐候树脂的NCO/OH的当量比为(0.6-1.2):1。
2.根据权利要求1所述的透明背板，其特征在于，所述毛面剂为气相二氧化硅、沉淀二氧化硅；所述毛面剂粒径为2μm-6μm，孔隙率为37％—50％。
3.根据权利要求2所述的透明背板，其特征在于，所述气相二氧化硅为有机硅表面处理过的二氧化硅。
4.根据权利要求2所述的透明背板，其特征在于，所述紫外吸收剂为二苯甲酮类、苯并三唑类或三嗪类化合物。
5.根据权利要求4所述的透明背板，其特征在于，所述紫外吸收剂为侧链含羟基、酯基、醚键官能团的二苯甲酮类、苯并三唑类或三嗪类化合物。
6.根据权利要求4所述的透明背板，其特征在于，所述异氰酸酯选自甲苯二异氰酸酯三聚体、异佛尔酮二异氰酸酯三聚体、六亚甲基二异氰酸酯三聚体、二苯基甲烷二异氰酸酯三聚体、甲苯二异氰酸酯二聚体、异佛尔酮二异氰酸酯二聚体、六亚甲基二异氰酸酯二聚体或二苯基甲烷二异氰酸酯二聚体中的一种或其混合物。
7.根据权利要求6所述的透明背板，其特征在于，所述氟碳树脂选自含羟基或氨基改性的四氟乙烯-乙烯基醚共聚物、四氟乙烯-乙烯基酯共聚物、三氟氯乙烯-乙烯基醚共聚物、三氟氯乙烯-乙烯基酯共聚物、聚氟乙烯(PVF)、聚偏氟乙烯(PVDF)或四氟乙烯-全氟烷基乙烯基醚共聚物(PFA)中的一种或其混合物。
8.根据权利要求7所述的透明背板，其特征在于，所述纳米级填料为金红石型钛白粉、氧化锌或氧化铈，粒径为20nm-80nm。
9.根据权利要求1所述的透明背板，其特征在于，所述耐候层为透明粘结层、透明PVF膜或透明PVDF膜，厚度为20μm-30μm。
10.根据权利要求1或9所述的透明背板，其特征在于，所述基材层为厚度150μm-300μm的聚酯薄膜；所述聚酯薄膜选自聚对苯二甲酸乙二醇酯(PET)树脂、聚对苯二甲酸丁二醇酯(PBT)树脂或聚对萘二甲酸乙二醇酯(PEN)树脂中的一种。
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| CN114437643A (zh) * | 2021-12-31 | 2022-05-06 | 苏州弘道新材料有限公司 | 一种新型轻质光伏组件封装板 |
| CN114621696A (zh) * | 2020-12-11 | 2022-06-14 | 苏州阿特斯阳光电力科技有限公司 | 一种光伏组件电池串用固定胶带及其制备方法和应用 |
| CN114806366A (zh) * | 2020-12-30 | 2022-07-29 | 常州威斯敦粘合材料有限责任公司 | 透明涂料半成品制备方法、耐磨及低透水率光伏透明背板 |
| CN115216044A (zh) * | 2022-08-25 | 2022-10-21 | 杭州和顺科技股份有限公司 | 一种高透光高击穿电压背板及其制备方法 |
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| CN116023877A (zh) * | 2023-03-30 | 2023-04-28 | 苏州弘道新材料有限公司 | 一种高耐候太阳能电池透明背板及其制备方法 |
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| CN114141896A (zh) * | 2021-11-24 | 2022-03-04 | 西安隆基绿能建筑科技有限公司 | 用于光伏组件前板或背板的复合材料及其制备方法与应用 |
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| CN115216044A (zh) * | 2022-08-25 | 2022-10-21 | 杭州和顺科技股份有限公司 | 一种高透光高击穿电压背板及其制备方法 |
| CN115651251A (zh) * | 2022-11-29 | 2023-01-31 | 宁波东旭成新材料科技有限公司 | 一种双面涂覆型太阳能背板膜 |
| CN116023877A (zh) * | 2023-03-30 | 2023-04-28 | 苏州弘道新材料有限公司 | 一种高耐候太阳能电池透明背板及其制备方法 |
| CN116333576A (zh) * | 2023-03-30 | 2023-06-27 | 苏州弘道新材料有限公司 | 一种耐候背板内层涂料组合物及其应用 |
| CN116333576B (zh) * | 2023-03-30 | 2023-12-29 | 苏州弘道新材料有限公司 | 一种耐候背板内层涂料组合物及其应用 |
| CN117511432A (zh) * | 2024-01-05 | 2024-02-06 | 山东旭贝新材料有限公司 | 转紫外透明型含氟聚合物膜及其制备方法 |
| CN117511432B (zh) * | 2024-01-05 | 2024-05-07 | 山东旭贝新材料有限公司 | 转紫外透明型含氟聚合物膜及其制备方法 |
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