CN112133779A - 新型透明光伏组件背板用基材及相应的背板 - Google Patents
新型透明光伏组件背板用基材及相应的背板 Download PDFInfo
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Abstract
本发明涉及一种新型透明光伏组件背板用基材及相应的背板,其主要特点是,该背板由外向内依次为耐候层/粘合层/聚对苯二甲酸‑1,4环己烷二甲醇酯层(PCT层)。耐候层的层数至少包括一层聚碳酸酯层,耐候层具有优异的耐候性、抗水解、高韧性、抗紫外黄变性能。PCT层具有良好的抗水解、耐水蒸汽透过性、介电性能和EVA粘结性能,且都具有高度的透明性,透光性良好。该新型透明光伏组件背板用基材及相应的背板避免了不耐水解的PET材料和含氟材料的使用。
Description
技术领域
本发明涉及光伏组件技术领域,具体是指一种新型透明光伏组件背板用基材及相应的背板。
背景技术
随着国际传统能源的日益贫乏,全球对新型能源的需求成为举世关注的焦点,而太阳能作为新型能源,不但取之不尽,用之不竭,而且具有清洁无污染、安全无公害等特点,备受全球关注并实现能源光伏转化的产业化。
在光伏发电领域,技术的发展趋势是光伏组件的高效发电,而双面高效太阳能电池的出现,大大提升了组件的发电效率。传统的组件中,目前国内用的最普遍的是杜邦生产的TPT型结构的背板,它是由上下两层氟膜和中间层的聚酯层(PET)复合而成。而双玻组件的出现,拓展了双面高效电池在光伏发电领域的应用,使得光伏双面发电成为了可能。但双玻组件的整体重量比较大,碎片率比较高,传统层压法效率低等问题,在一定程度上制约了其应用。
因此,一种透明背板的出现则很好的避免了上述问题,该透明背板除了满足常规背板的力学性能、耐候性、水汽透过率外,还需要保证具有较高的透光率和较低的雾度,以及优异的抗紫外老化性能等。该透明背板在光伏建筑一体化,玻璃幕墙,温室花房以及公路、铁路、机场等需严格防眩光的环境下使用具有独特的优势。
传统的背板中通常用含氟薄膜作为耐候层,用PET层作为基材层。
如专利CN 203826402 U一种透明太阳能电池背板及太阳能电池组件中报道,该透明太阳能电池背板包括透明基层、耐候透明膜层,还包括所述透明基层的一面上的耐候透明涂层以及形成在所述透明基层另一面与所述耐候透明膜层粘接的透明高分子胶黏剂层。其中透明基层为透明PET基层,耐候透明膜层为耐UV透明聚氟乙烯膜层、透明聚偏氟乙烯膜层、透明高耐候PET膜层、透明改性聚甲基丙烯酸甲酯膜层中的一种。
专利CN 106024955 A一种易清洁太阳能电池背板,包括PET基材,所述PET基材的一侧通过粘结层连接耐候层,于所述耐候层的上表面设置氟树脂涂层,于所述氟树脂涂层的表面设置疏水层,于所述PET基材的另一端通过粘结层连接耐候粘结层。该专利中使用了PET和含氟材料。
专利CN204303833 U太阳能电池背板,包括自上而下依次设置的透明耐候性PC膜层、PET膜层、粘结层及用于吸收10~400nm的紫外光的增效膜层,透明耐候性PC膜层与PET膜层共挤成型,粘结层的两面分别与PET膜层与增效膜层贴合。该专利中虽用耐候PC膜层取代了含氟材料,但仍使用了PET材料。
专利CN 102067328 A太阳能电池用层合片材及使用其的太阳能电池组件,该层合片材包括背板基材和密封材料层,通过熔融挤出层压法将密封材料层层合到背板基材的。所述背板基材使用氟树脂或聚酯树脂。所述氟树脂为选自四氟乙烯·乙烯共聚物、四氟乙烯·六氟丙烯共聚物、四氟乙烯·全氟烷基乙烯基醚共聚物、聚氯三氟乙烯、氯三氟乙烯·乙烯共聚物、聚氟乙烯及聚偏氟乙烯中的至少一种。所述的聚酯树脂选自聚对苯二甲酸乙二醇酯(PET)、聚萘二甲酸乙二醇酯(PEN)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸环己烷二甲醇酯(PCT)中的至少一种。该专利中只是提到上述材料可用于背板基材,但并没有明确如何制成背板。
但是氟塑料成本高昂,环境不友好,大大限制了其发展空间。PET层作为耐候层,PET主链含有大量的酯基,在湿热条件下容易发生水解。湿热老化初期水分在PET表面吸附,缓慢渗透,由于随着时间延长,水对PET的刻蚀和溶剂化作用,PET的结晶度逐渐升高,其表面微孔和龟裂增加,与此同时PET分子链中酯键受到水分子攻击而发生断裂,形成分子链更短的PET,在水增速的作用下结晶度进一步增加,PET脆性增加,水分向PET内部渗透加速,以上过程不断重复,最终使PET失去原有的力学性能和水气阻隔性能。而温度的升高,一方面加速PET结晶,从而增加其龟裂程度;另外还增加了端羧基的活泼性,加速水解反应的发生。另背板导热效果差,透明原材料成本高,制备的背板透明度较低,雾度较差,影响了太阳能电池的发电效率。
因此,寻找一种避免使用不耐水解的PET材料和含氟材料的透明背板成为研究的热点。
发明内容
本发明的目的是克服了上述现有技术的缺点,提供了一种新型透明光伏组件背板用基材及相应的背板,该背板具有优异的耐候性、透光性好、工艺相对简单、避免了不耐水解的PET材料和含氟材料的使用,对环境友好。
为了实现上述目的,本发明的新型透明光伏组件背板用基材,其主要特点是,所述的基材由外向内依次包括耐候层、粘合层、聚对苯二甲酸-1,4环己烷二甲醇酯层(PCT层),所述的耐候层包括至少一层聚碳酸酯层。
该基材可直接为透明背板,也可为透明背板的一部分。
聚碳酸酯层具有优异的耐候性、抗水解、高韧性、抗紫外黄变性能。
耐候性PCT层具有良好的抗水解、耐水蒸汽透过性、介电性能和EVA粘结性能,且都具有高度的透明性,透光性良好。
其中,耐候层还可以包括位于所述的至少一层聚碳酸酯层的外侧的至少一层表面耐磨层;耐候层还可以包括位于所述的至少一层聚碳酸酯层的内侧的至少一层功能改性层。表面耐磨层和功能改性层可以通过熔融共挤方式制备耐候层,功能改性层也可通过表面涂布制成。
所述的表面耐磨层为聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层、或经纳米二氧化硅、超细活性硅微粉或超细改性氧化铝等改性剂进行耐磨性改性的改性聚碳酸酯层。其中聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层为耐磨性材料。
所述的功能改性层为聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层或丙烯酸类涂层。功能改性层为用于提高粘结性、阻隔紫外等作用的各类聚酯层,可以是与聚碳酸酯一起共挤或者在聚碳酸酯层表面涂布制得。优选地,采用聚甲基丙烯酸甲酯或改性聚甲基丙烯酸甲酯与聚碳酸酯共挤得到,或在聚碳酸酯层的表面涂布丙烯酸类涂层。
所述的耐候层的总厚度为20~300μm,其中至少一层聚碳酸酯层占所述的耐候层的总厚度的50%~100%,例如,至少一层聚碳酸酯层的总厚度为30~250μm。
较佳地,所述的PCT层中PCT树脂的含量≥80wt%,PCT层的厚度为25~250μm。
较佳地,所述的粘合层通过胶黏剂覆合耐候层和PCT层而形成。粘合层的厚度为5~50μm,聚碳酸酯层和PCT层的层间粘接力达到4N/cm以上,具有优异的耐湿热老化和紫外黄变性能。
较佳地,所述新型透明背板的透光率>80%。
采用了该发明中的新型透明光伏组件背板用基材及相应的背板具有优异的耐候性、透光性好、工艺相对简单、避免了不耐水解的PET材料和含氟材料的使用,对环境友好。
附图说明
图1为本发明的新型透明光伏组件背板中耐候层为一层结构时的结构示意图。
图2为本发明的新型透明光伏组件背板中耐候层为表面耐磨层和聚碳酸酯层两层结构时的结构示意图。
图3为本发明的新型透明光伏组件背板中耐候层为三层结构时的结构示意图。
图4为本发明的新型透明光伏组件背板中耐候层为聚碳酸酯层和功能改性层两层结构时的结构示意图。
附图标记
1 PCT层
2 粘合层
3 聚碳酸酯层
4 表面耐磨层
5 功能改性层
具体实施方式
为了能够更清楚地描述本发明的技术内容,下面结合具体实施例来进行进一步的描述。
如图1所示,为本发明提供新型透明光伏组件背板用基材的第一实施例,该新型透明光伏组件背板的基材由外向内依次为聚碳酸酯层3、粘合层2、聚对苯二甲酸-1,4环己烷二甲醇酯层1(PCT层)。该基材可直接为透明背板,也可为透明背板的一部分。
如图2所示,为本发明提供的新型透明光伏组件背板用基材的第二实施例,该背板的基材由外向内依次为表面耐磨层4、聚碳酸酯层3、粘合层2、聚对苯二甲酸-1,4环己烷二甲醇酯层1(PCT层)。该基材可直接为透明背板,也可为透明背板的一部分。
其中表面耐磨层4可以通过对聚碳酸酯添加改性剂进行耐磨性改性或选择耐磨性好的材料而获得,表面耐磨层4与聚碳酸酯层3通过熔融共挤复合。
表面耐磨层4可以为纳米二氧化硅、超细活性硅微粉或超细改性氧化铝等改性剂改性的改性聚碳酸酯层。
表面耐磨层4可以为聚甲基丙烯酸甲酯层或改性聚甲基丙烯酸甲酯层。
如图3所示,为本发明提供的新型透明光伏组件背板用基材的第三实施例,该背板的基材由外向内依次为表面耐磨层4、聚碳酸酯层3、功能改性层5、粘合层2、聚对苯二甲酸-1,4环己烷二甲醇酯层1(PCT层)。该基材可直接为透明背板,也可为透明背板的一部分。
其中,功能改性层是为提高粘结性、阻隔紫外等作用的各类聚酯层,可以是与聚碳酸酯一起共挤或者在聚碳酸酯层表面涂布制得。例如,采用聚甲基丙烯酸甲酯或改性聚甲基丙烯酸甲酯与聚碳酸酯共挤得到,或在聚碳酸酯层的表面涂布丙烯酸类涂层。
如图4所示,为本发明提供的新型透明光伏组件背板用基材的第四实施例,该背板的基材由外向内依次为聚碳酸酯层3、功能改性层5、粘合层2、聚对苯二甲酸-1,4环己烷二甲醇酯层1(PCT层)。该基材可直接为透明背板,也可为透明背板的一部分。
其中,功能改性层是为提高粘结性、阻隔紫外等作用的各类聚酯层,可以是与聚碳酸酯一起共挤或者在聚碳酸酯层表面涂布制得。例如,采用聚甲基丙烯酸甲酯或改性聚甲基丙烯酸甲酯与聚碳酸酯共挤得到,或在聚碳酸酯层的表面涂布丙烯酸类涂层。
以下提供了本发明的具体实施例1~11,以详述本发明提供的基材。
实施例1
本实施例1中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,两层的总厚度为20μm,聚碳酸酯层的厚度为两层总厚度的50%;
步骤(2):通过螺杆挤出,制备厚度为25μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为80wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为5μm。
实施例2
本实施例2中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,两层的总厚度为30μm,聚碳酸酯层的厚度为两层总厚度的50%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为90wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例3
本实施例3中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为纳米二氧化硅、超细活性硅微粉、超细改性氧化铝、紫外吸收剂等改性剂改性的聚碳酸酯,两层的总厚度为50μm,聚碳酸酯层的厚度为两层总厚度的80%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例4
本实施例4中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备表面聚碳酸酯层,表面耐磨层为未经改性的聚甲基丙烯酸甲酯,两层的总厚度为50μm,聚碳酸酯层的厚度为两层总厚度的80%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例5
本实施例5中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,两层的总厚度为50μm,聚碳酸酯层的厚度为两层总厚度的20%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例6
本实施例6中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融挤出制备聚碳酸酯层,总厚度为50μm。
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例7
本实施例7中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,功能改性层为改性聚甲基丙烯酸甲酯,三层的总厚度为50μm,聚碳酸酯层的厚度为总厚度的80%,表面耐磨层和功能特性层的厚度各为总厚度的10%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例8
本实施例8中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,在耐候聚碳酸酯层一侧涂覆一层功能改性层,功能改性层为丙烯酸类涂层,三层的总厚度为50μm,聚碳酸酯层的厚度为总厚度的80%,表面耐磨层和功能特性层的厚度各为总厚度的10%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
实施例9
本实施例9中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,两层的总厚度为250μm,聚碳酸酯层的厚度为两层总厚度的90%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为30μm。
实施例10
本实施例10中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,表面耐磨层为耐磨和耐紫外改性的聚甲基丙烯酸甲酯,两层的总厚度为300μm,聚碳酸酯层的厚度为两层总厚度的99%;
步骤(2):制备厚度为250μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为99wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为50μm。
实施例11
本实施例11中新型透明光伏组件背板用基材的制备包括如下步骤:
步骤(1):通过熔融共挤制备聚碳酸酯层,功能改性层为改性聚甲基丙烯酸甲酯,两层的总厚度为50μm,聚碳酸酯层的厚度为总厚度的80%,功能特性层的厚度为总厚度的20%;
步骤(2):制备厚度为200μm的耐紫外改性的PCT层薄膜,PCT层薄膜中PCT树脂的含量为95wt%。
步骤(3):聚碳酸酯层与PCT层通过胶黏剂覆合而成,粘合层的厚度为10μm。
本发明的实施例1~11制得的新型耐磨透明光伏组件背板用基材的性能检测数据见表一。
按照背板透光率和耐紫外老化测试标准要求,测试样品在200KWh/m2的透光率、水蒸气透过率和黄色指数b,计算△b。
按照ASTMD 968-83落砂法实验有机涂层的耐磨性测试背板的耐磨性。
表一
总之,采用了该发明中的新型透明光伏组件背板用基材及相应的背板具有优异的耐候性、透光性好、工艺相对简单、避免了含氟材料和PET材料的使用,对环境友好。
在此说明书中,本发明已参照其特定的实施例作了描述。但是,很显然仍可以作出各种修改和变换而不背离本发明的精神和范围。因此,说明书和附图应被认为是说明性的而非限制性的。
Claims (13)
1.一种新型透明光伏组件背板用基材,其特征在于,所述的基材由外向内依次包括耐候层、粘合层和聚对苯二甲酸-1,4环己烷二甲醇酯层,所述的耐候层包括至少一层聚碳酸酯层。
2.根据权利要求1所述的新型透明光伏组件背板用基材,其特征在于,所述的耐候层还包括至少一层表面耐磨层,所述的至少一层表面耐磨层位于所述的至少一层聚碳酸酯层的外侧。
3.根据权利要求2所述的新型透明光伏组件背板用基材,其特征在于,所述的至少一层聚碳酸酯层和至少一层表面耐磨层通过熔融共挤方式制备。
4.根据权利要求2所述的新型透明光伏组件背板用基材,其特征在于,所述的表面耐磨层为聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层、或经纳米二氧化硅、超细活性硅微粉或超细改性氧化铝改性的改性聚碳酸酯层。
5.根据权利要求2所述的新型透明光伏组件背板用基材,其特征在于,所述的耐候层还包括至少一层功能改性层,所述的至少一层功能改性层位于所述的至少一层聚碳酸酯层的内侧。
6.根据权利要求5所述的新型透明光伏组件背板用基材,其特征在于,所述的功能改性层为聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层或丙烯酸类涂层。
7.根据权利要求5所述的新型透明光伏组件背板用基材,其特征在于,所述的至少一层聚碳酸酯层、至少一层表面耐磨层和至少一层功能改性层通过熔融共挤方式或表面涂布方式制备。
8.根据权利要求1所述的新型透明光伏组件背板用基材,其特征在于,所述的耐候层还包括至少一层功能改性层,所述的至少一层功能改性层位于所述的至少一层聚碳酸酯层的内侧。
9.根据权利要求8所述的新型透明光伏组件背板用基材,其特征在于,所述的功能改性层为聚甲基丙烯酸甲酯层、改性聚甲基丙烯酸甲酯层或丙烯酸类涂层。
10.根据权利要求8所述的新型透明光伏组件背板用基材,其特征在于,所述的至少一层聚碳酸酯层和至少一层功能改性层通过熔融共挤方式或表面涂布方式制备。
11.根据权利要求1所述的新型透明光伏组件背板用基材,其特征在于,所述的耐候层的总厚度为20~300μm,所述的至少一层聚碳酸酯层占所述的耐候层的总厚度的50%~100%。
12.根据权利要求1所述的新型透明光伏组件背板用基材,其特征在于,所述的聚对苯二甲酸-1,4环己烷二甲醇酯层中PCT树脂的含量≥80wt%,厚度为25~250μm;
优选地,所述的粘合层的厚度为5~50μm,粘接力达到4N/cm以上;
优选地,所述的基材的透光率>80%。
13.一种新型透明光伏组件背板,其特征在于,所述的背板包括权利要求1至12中任一项所述的基材。
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