CN111718661B - 网格化封装胶膜及其制备方法 - Google Patents
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- CN111718661B CN111718661B CN202010519913.XA CN202010519913A CN111718661B CN 111718661 B CN111718661 B CN 111718661B CN 202010519913 A CN202010519913 A CN 202010519913A CN 111718661 B CN111718661 B CN 111718661B
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- Laminated Bodies (AREA)
Abstract
本发明涉及一种网格化封装胶膜及其制备方法,属于光伏电池组件技术领域。网格化封装胶膜包含有胶膜表层,用于阻隔紫外线,并为反射网格层提供附着基础;反射网格层,具有网格状结构,用于反射光线,反射网格层的轮廓与位于两片电池片的间隙以及电池片与组件边缘的间隙相适配;透明胶膜层,用于封装光伏背板或背面光伏钢化玻璃,设置于所述反射网格层远离所述胶膜表层的一侧。该封装胶膜具有反射网格层结构均匀稳定且不会随着透明胶膜层的流动交联变形的优势,并且,作为反射网格层的形成基础的胶膜表层也可以阻挡紫外线,防止位于其后的反射层、胶膜层及背板的老化变形。
Description
技术领域
本发明涉及光伏电池组件技术领域,具体涉及一种网格化封装胶膜及其制备方法。
背景技术
对于光伏发电领域而言,高转换效率和低制造成本一直是其追求的目标。目前,光伏组件中由于电池片之间存在间隙,照射于该间隙处的光线无法被电池片充分吸收利用;并且,可透光的电池片,也会造成能量的损失,导致光伏组件的效率低于电池片效率。
白色高反射背板能够利用间隙处的光线,背层胶膜采用白色胶膜同样能够部分利用该光线,且功率增益高于白色背板。二者的原理均为将间隙处的光线反射至前层玻璃,并在玻璃与空气的界面处发生反射甚至全反射,最终将光线射向电池片正面。
然而,对于双面电池而言,背层若采用白色胶膜,则会遮挡背面的太阳光,无法发挥双面电池的优势。针对上述问题,网格化胶膜应运而生,其通过在电池片间隙处设置高反射的胶膜,电池片区域设置成透明状,不仅能够充分利用间隙处的太阳光,而且完全不遮挡背面光线,完美兼容双面电池,如申请公布号为CN 110776842 A的中国发明专利公开的一种局部高反光的封装胶膜及用途,该封装胶膜由反射层和基体层构成,在380nm-1200nm的波长范围内,反射层在具有高反射率,基体层具有高的透光率,且反射层呈网格化图案分布在无色透明基体层的一侧,并位于两片电池片的间隙以及电池片与组件边缘的间隙,该光伏封装胶膜产品具有生产工艺简便,产品性能稳定,性价比高的优点。
然而,现有技术中,网格化的反射层往往是以胶膜层作为基底而形成的,胶膜层自身的薄厚难以控制均匀,易导致网格厚薄度不均,且在制备组件-真空层压过程中,随着封装胶膜在高温、真空条件下流动交联,还容易导致网格化反射层的形状“跑偏”,导致光线得不到高效的反射,降低了光伏电池组件的发电效率。
发明内容
针对上述问题,本发明以提供一种网格化封装胶膜为目的之一,以提供一种该封装胶膜的制备方法为目的之二而提供了下述技术方案,该封装胶膜具有反射网格层结构均匀稳定且不会随着透明胶膜层的流动交联变形的优势,并且,作为反射网格层的形成基础的胶膜表层也可以阻挡紫外线,防止位于其后的反射层、胶膜层及背板的老化变形。
本发明解决上述问题的技术方案如下:
网格化封装胶膜,包含有:
胶膜表层,用于阻隔紫外线,并为反射网格层提供附着基础;
反射网格层,具有网格状结构,用于反射光线,所述反射网格层设置于所述胶膜表层具有平整面的一侧,反射网格层的轮廓与位于两片电池片的间隙以及电池片与组件边缘的间隙相适配;
透明胶膜层,用于封装光伏背板或背面光伏钢化玻璃,设置于所述反射网格层远离所述胶膜表层的一侧。
作为上述技术方案的优选,所述胶膜表层的厚度为15~50μm,所述反射网格层的厚度为5~40μm,所述透明胶膜层的厚度为100~500μm。
作为上述技术方案的优选,所述胶膜表层为含氟涂层。
作为上述技术方案的优选,所述胶膜表层包含有聚四氟乙烯树脂、聚三氟氯乙烯树脂、聚偏氟乙烯树脂、四氟乙烯-乙烯共聚物、三氟氯乙烯-乙烯共聚物中的一种或多种的混合物,还包含有环氧树脂、光稳定剂、紫外线吸收剂、固化剂、流平剂、分散剂、催化剂以及其他助剂。
作为上述技术方案的优选,所述反射网格层为含氟涂层。
作为上述技术方案的优选,所述反射网格层包含有聚氟乙烯、聚偏氟乙烯、四氟乙烯与乙烯的共聚物、四氟乙烯与乙烯基酯或乙烯基醚的共聚物、三氟氯乙烯与乙烯基酯或乙烯基醚的共聚物、聚全氟乙丙烯中的一种或多种的混合物,还包含有固化剂、紫外光吸收剂、抗氧剂、颜料、填料、染料、流平剂、分散剂、催化剂以及其他助剂。
作为上述技术方案的优选,所述透明胶膜层为EVA胶膜。
作为上述技术方案的优选,所述透明胶膜层包含有乙烯、丙烯、乙酸乙烯酯中的一种或几种的无规共聚物,还包含有交联剂、分散剂、填充剂、润滑剂、紫外助剂、抗氧化剂、阻燃剂、发泡剂和发泡助剂。
上述任一技术方案中提及的网格化封装胶膜的制备方法,包含有如下步骤:
①在离型防粘膜层上涂覆胶膜表层;
②在涂覆好的所述胶膜表层表面形成平整面,将网格状的反射网格层形成至所述平整面上;
③透明胶膜层的原料经高温熔融后形成至包含有反射网格层的所述平整面上,冷却形成透明胶膜层;
④将所述离型防粘膜层与所述胶膜表层分离,分离后,结合在一起的所述胶膜表层、所述反射网格层和所述透明胶膜层即构成网格化封装胶膜。
作为上述技术方案的优选,步骤②中,所述反射网格层通过微凹网纹涂布、丝网印刷和喷墨打印中的一种方式形成至所述平整面上。
综上所述,本申请实施例具有以下有益效果:
1)本申请实施例所述的封装胶膜,其内部的反射网格层结构均匀稳定、不会随着透明胶膜层的流动交联而变形跑偏。
2)进一步的,作为反射网格层的形成基础的胶膜表层也可以阻挡紫外线,防止位于其后的反射层、胶膜层及背板的老化变形。
3)更进一步的,该封装胶膜的制备方法简单易行,适于大规模生产。
附图说明
图1为本申请实施例所述的网格化封装胶膜层状结构示意图;
图2为本申请实施例所述的网格化封装胶膜制备时步骤③完结时的层状结构示意图;
图3为本申请实施例所述的网格化封装胶膜的俯视结构示意图;
图4为本申请实施例所述的不同厚度的胶膜表层的透光性能随光波长的变化趋势图;
图5为本申请实施例所述的不同厚度的反射网格层的反射性能随光波长的变化趋势图;
图中,1-胶膜表层、2-反射网格层、3-透明胶膜层、a-离型防粘膜层。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。本发明中的实施例,本领域普通技术人员在没有做创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
下面以实施例对本发明进行详细说明。
实施例:参考图1,网格化封装胶膜,通常用于光伏发电组件的后层封装胶膜,即组装成光伏发电组件后,其朝向阳光的方向尚存在电池片、前封装胶膜和正面光伏钢化玻璃的等构件。
网格化封装胶膜由相邻于电池片依次设置的胶膜表层1、反射网格层2和透明胶膜层3构成。
其中,胶膜表层1为透明且具有耐候性能的层状体,其厚度为15~50μm,且容易形成平整的表面,用于提供反射网格层2的附着基础,由于其表面平整,因此可以容易的控制反射网格层2在其上形成厚度一致的网格层,这样,就能够避免反射网格层2由于厚度不均一所发生的局部流出/变形现象,有效的防止了反射网格层2随着透明胶膜层3的流动交联而跑偏,在优选的实施例中,胶膜表层1还可以阻隔紫外线,防止反射网格层2、透明胶膜层3和背板在紫外线的作用下老化变形;
反射网格层2,厚度为5~40μm,具有网格状结构,用于反射两片电池片的间隙以及电池片与组件边缘的间隙所投过来的光线,提升光伏组件的发电效率;
透明胶膜层3,厚度为100~500μm,用于封装光伏背板或背面光伏钢化玻璃。
从配方角度看,本实施例中的胶膜表层1包含有聚四氟乙烯树脂、聚三氟氯乙烯树脂、聚偏氟乙烯树脂、四氟乙烯-乙烯共聚物、三氟氯乙烯-乙烯共聚物中的一种或多种的混合物,还包含有环氧树脂、光稳定剂、紫外线吸收剂、固化剂、流平剂、分散剂、催化剂以及其他助剂。
其中,环氧树脂选自双酚A型环氧树脂、双酚F型环氧树脂、脂肪族环氧树脂;光稳定剂和紫外线吸收剂为水杨酸酯类、苯酮类、苯并三唑类、取代丙烯晴类、三嗪类和受阻胺类;固化剂选自六亚甲基二异氰酸酯三聚体、六亚甲基二异氰酸酯缩二脲、二苯甲烷二异氰酸酯三聚体、异佛尔酮二异氰酸酯三聚体、异佛尔酮二异氰酸酯预聚体;分散剂为含颜料亲和基团的嵌段共聚物类分散剂;流平剂选自聚醚改性聚硅氧烷流平剂、芳烷基改性聚硅氧烷流平剂、聚酯改性聚硅氧烷流平剂、反应型聚硅氧烷流平剂,催化剂为辛酸亚锡,其他助剂填料选自纳米二氧化钛、透明粉、抗划粉、陶瓷微珠、白炭黑、玻璃粉、消光粉;溶剂选自二甲苯、丙二醇甲醚醋酸酯。
实施例中的比例均为质量百分比,具体的实例可以是:
1)将氟碳树脂(40%~50%)、环氧树脂(2%~3%)、流平剂(0.2%~0.5%)、分散剂(0.2%~0.5%),光稳定剂和紫外线吸收剂(12%~20%),其他填料助剂(5%~10%),溶剂(20%~25%)混合搅拌均匀成透明氟碳涂料主剂;
2)将上述透明涂料主剂、固化剂和溶剂按一定比例室温搅拌均匀成透明氟碳涂料;
3)选择125μm厚度的PET型离型防粘膜作为基材,通过狭缝挤出涂布方式或微凹辊辊涂的方式将透明氟碳涂料涂布在基材上,通过高温(150℃~200℃)固化3~5min的方式,在基材表面形成一层致密稳定的胶膜表层1,涂层厚度2μm。
还可以是:
与上述实施例的配方一致,但胶膜表层1的厚度分别为5μm、7μm、9μm、11μm、13μm、15μm、17μm的实施例;
对上述实施例中的胶膜表层1进行透光率测试:按照GB/T-2410 ASTM D1003《透明塑料透光率和雾度试验方法》,其结果参考说明书附图4。
将不同厚度的耐候透明涂层与防粘膜分开,将撕下的不同厚度的耐候透明涂层测试其紫外截至能力与透光性能,不同厚度的涂层的透光性能(400到1000nm)几乎无差异,当涂层厚度≥13μm时,380nm以下全截至,涂层厚度≤5μm时,10~20%的紫外光透过,因此实施例优选的胶膜表层的厚度≥15μm。
反射网格层2包含有聚氟乙烯、聚偏氟乙烯、四氟乙烯与乙烯的共聚物、四氟乙烯与乙烯基酯或乙烯基醚的共聚物、三氟氯乙烯与乙烯基酯或乙烯基醚的共聚物、聚全氟乙丙烯中的一种或多种的混合物,还包含有固化剂、紫外光吸收剂、抗氧剂、颜料、填料、染料、流平剂、分散剂、催化剂以及其他助剂。
其中,抗氧剂和紫外线吸收剂为水杨酸酯类、苯酮类、苯并三唑类、取代丙烯晴类、三嗪类和受阻胺类;固化剂选自六亚甲基二异氰酸酯三聚体、六亚甲基二异氰酸酯缩二脲、二苯甲烷二异氰酸酯三聚体、异佛尔酮二异氰酸酯三聚体、异佛尔酮二异氰酸酯预聚体;分散剂为含颜料亲和基团的嵌段共聚物类分散剂;流平剂选自聚醚改性聚硅氧烷流平剂、芳烷基改性聚硅氧烷流平剂、聚酯改性聚硅氧烷流平剂、反应型聚硅氧烷流平剂;催化剂为辛酸亚锡;其他助剂、颜料、填料选自钛白粉、消光粉、氧化镁、氧化铝、硫酸钡、碳酸钙、铜铬黑、铁铬黑、氧化铁黑;
具体的实例可以是:
1)将氟碳树脂(50%~60%)、流平剂(0.2%~0.5%)、分散剂(0.5%~1%),抗氧剂和紫外线吸收剂(0.1%~0.5%),钛白粉(15~25%),其他填料助剂(5%~10%),溶剂(10%~15%)混合搅拌均匀成反射层涂料主剂。
2)将上述反射层涂料主剂、固化剂和溶剂按一定比例室温搅拌均匀成反射层涂料,
3)在15μm后的胶膜表层1上涂布反射网格层2,通过高温(150℃~200℃)固化3~5min,厚度3μm。
还可以是:
与上述实施例的配方一致,但反射网格层2的厚度分别为6μm、9μm、12μm、15μm、20μm、25μm的实施例;
对上述实施例中的反射网格层2进行反射率测试:参照GB/T 29848中反射率的测试方法,其结果参考说明书附图5。
将不同厚度的反射网格层测试其反射率,反射网格层的反射率随着涂层厚度的增加而增加,因此实施例的反射网格层的厚度优选≥20μm。
透明胶膜层3包含有乙烯、丙烯、乙酸乙烯酯中的一种或几种的无规共聚物,还包含有交联剂、偶联剂、分散剂、填充剂、润滑剂、紫外助剂、抗氧化剂、阻燃剂、发泡剂和发泡助剂。
其中,交联剂选自过氧化-2-乙基己酸叔丁酯、二季戊四醇六丙烯酸酯和丙氧化三羟甲基丙烷三丙烯酸酯;抗氧化剂和紫外线吸收剂为苯酮类、苯并三唑类、取代丙烯晴类、三嗪类和受阻胺类;分散剂、填充剂、润滑剂选自碳酸镁、碳酸钡、硫酸钡、硫酸钡、硫酸钙、磷酸钙、滑石粉、高岭土;阻燃剂为磷酸三苯酯、聚磷酸铵;发泡剂为偶氮二甲酰胺,发泡助剂选自尿素、脲的衍生物、苯二甲酸、乙醇胺。
具体的实例可以是:
将乙烯-醋酸乙烯共聚物(60%~75%)、硅烷类助剂(20~25)、交联剂(1%~3%)、分散剂、填充剂、润滑剂(0.3%~2%)、紫外助剂、抗氧化剂(0.5%~2%)、阻燃剂(0.1~0.2%)、发泡剂和发泡助剂(0.1%~0.5%)在150~200℃条件下熔融流延成膜,制成200μm的透明胶膜。
还可以是:
与上述实施例的配方一致,但反射网格层2的厚度分别为300μm、400μm、500μm的实施例。
所述的网格化封装胶膜是将胶膜表层1、反射网格层2、透明胶膜层中的不同实施例任意组合。
容易理解及实现的,本申请所述的网格化封装胶膜可应用于双面发电、叠瓦、半片等高效的发电组件和常规组件。
本申请所述的反射网格层2采用间接性转移网格的方式设置于封装胶膜内,具体的制备方法,包括如下步骤:
①参考上述配方,在PET型离型防粘膜层a上涂覆胶膜表层1,该胶膜表层1具有透光性好、成膜性好、紫外阻隔性好、粘附性好的特点,可单独成膜,与各类有机/无机材料相容性好,横向(TD)/纵向(MD)性能均一,不会因为老化导致降解失效;
②在涂覆好的胶膜表层1表面形成平整面,将网格状的反射网格层2形成至所述平整面上,网格的具体形状可以根据不同的组件需求单独设计,在不同的实施例中,反射网格层2的形成方式可以是微凹网纹涂布、丝网印刷,也可以是喷墨打印,胶膜表层1保证了在透明胶膜层3层压使用过程中发生交联流动时,反射网格层2能够不发生形变和跑偏;
③透明胶膜层3的原料经高温熔融后流延在包含有反射网格层2的所述平整面上,冷却形成透明胶膜层3,此时的产品结构参考图2;
④将离型防粘膜层a与胶膜表层1分离,分离后,结合在一起的胶膜表层1、反射网格层2和透明胶膜层3即构成网格化封装胶膜,网格化封装胶膜的俯视图可参考图3。
Claims (7)
1.网格化封装胶膜,其特征在于,包含有:
胶膜表层(1),用于形成反射网格层(2)提供附着基础;
反射网格层(2),具有网格状结构,用于反射光线,所述反射网格层(2)设置于所述胶膜表层(1)具有平整面的一侧;
透明胶膜层(3),用于封装光伏背板或背面光伏钢化玻璃,设置于所述反射网格层(2)远离所述胶膜表层(1)的一侧;
所述胶膜表层(1)的厚度为15~50μm,所述反射网格层(2)的厚度为5~40μm,所述透明胶膜层(3)的厚度为100~500μm;
所述胶膜表层(1)为含氟涂层,所述反射网格层(2)为含氟涂层。
2.根据权利要求1所述的网格化封装胶膜,其特征在于:所述胶膜表层(1)包含有聚四氟乙烯树脂、聚三氟氯乙烯树脂、聚偏氟乙烯树脂、四氟乙烯-乙烯共聚物、三氟氯乙烯-乙烯共聚物中的一种或多种的混合物,还包含有环氧树脂、光稳定剂、紫外线吸收剂、固化剂、流平剂、分散剂、催化剂以及其他助剂。
3.根据权利要求1所述的网格化封装胶膜,其特征在于:所述反射网格层(2)包含有聚氟乙烯、聚偏氟乙烯、四氟乙烯与乙烯的共聚物、四氟乙烯与乙烯基酯或乙烯基醚的共聚物、三氟氯乙烯与乙烯基酯或乙烯基醚的共聚物、聚全氟乙丙烯中的一种或多种的混合物,还包含有固化剂、紫外光吸收剂、抗氧剂、颜料、填料、染料、流平剂、分散剂、催化剂以及其他助剂。
4.根据权利要求1所述的网格化封装胶膜,其特征在于:所述透明胶膜层(3)为EVA胶膜。
5.根据权利要求4所述的网格化封装胶膜,其特征在于:所述透明胶膜层(3)包含有乙烯、丙烯、乙酸乙烯酯中的一种或几种的无规共聚物,还包含有交联剂、分散剂、填充剂、润滑剂、紫外助剂、抗氧化剂、阻燃剂、发泡剂和发泡助剂。
6.权利要求1~5中任一条所述的网格化封装胶膜的制备方法,其特征在于,包含有如下步骤:
①在离型防粘膜层(a)上涂覆胶膜表层(1);
②在涂覆好的所述胶膜表层(1)表面形成平整面,将网格状的反射网格层(2)形成至所述平整面上;
③透明胶膜层(3)的原料经高温熔融后形成至包含有反射网格层(2)的所述平整面上,冷却形成透明胶膜层(3);
④将所述离型防粘膜层(a)与所述胶膜表层(1)分离,分离后,结合在一起的所述胶膜表层(1)、所述反射网格层(2)和所述透明胶膜层(3)即构成网格化封装胶膜。
7.根据权利要求6所述的网格化封装胶膜的制备方法,其特征在于:步骤②中,所述反射网格层(2)通过微凹网纹涂布、丝网印刷和喷墨打印中的一种方式形成至所述平整面上。
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