CN112659678A - 用于太阳能电池的背板及其制法 - Google Patents
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Abstract
本发明公开一种用于太阳能电池的背板及其制法。用于太阳能电池的背板包括一聚烯烃叠层结构和一保护层,保护层设置于聚烯烃叠层结构上。聚烯烃叠层结构包括一反射层以及设置于反射层上的一透光层;其中,透光层包括一连续相和分散于连续相中的一分散相,连续相是由聚烯烃所形成,分散相是由橡胶弹性体所形成,所述分散相在所述透光层中的含量为10重量百分比至25重量百分比。
Description
技术领域
本发明涉及一种背板及其制法,特别是涉及一种用于太阳能电池的背板及其制法。
背景技术
一般而言,太阳能电池模块主要是由玻璃盖板、乙烯-醋酸乙烯共聚物(ethylene-vinyl acetate copolymer,EVA)薄膜、太阳能电池和背板(back panel)所组成。其中,背板是整个太阳能电池模块中与外界接触面积最大的构件,背板的设置不仅可支撑整个太阳能电池模块,更可阻隔太阳能电池与外界环境,达到保护太阳能电池的效果。
为了接收大量的光能,太阳能电池模块通常会架设于户外,但如此一来,太阳能电池模块需具备良好的耐候性和耐热性,以承受户外的日晒雨淋。并且,太阳能电池模块需具备良好的阻隔性和耐冲击性,以避免外界环境中的微颗粒、液体或水气渗入,若外界的微颗粒、液体或水气不幸侵入太阳能电池模块,则可能会造成太阳能电池的毁损,甚至影响太阳能电池的光电转换效率。因此,对太阳能电池模块而言,背板的耐候性、耐热性、阻隔性和耐冲击性,是影响太阳能电池模块的使用寿命的重要因素。
传统用于太阳能电池的背板主要包括:可作为穿透层的一透明聚烯烃薄膜、可作为反射层的一聚酯薄膜(例如:聚对苯二甲酸乙二酯薄膜)以及一保护层。然而,由于上述各层间材料的差异,在加工制备背板时,需于聚酯薄膜上的相对两面上分别进行复合加工,以于聚酯薄膜的相对两面分别形成穿透层和保护层。也就是说,传统的背板至少需经过两次复合加工,才可完成制备。然而,复合加工的成本较高也较容易产生瑕疵,并且,在复合加工的过程中涉及了黏着剂的使用,黏着剂会随时间老化,而导致黏着力下降。此外,若有水气渗入背板的结构内,黏着剂的黏着效果也会因此被削弱,而可能导致背板的叠层结构发生剥离现象。
发明内容
本发明所要解决的技术问题在于,针对现有技术的不足提供一种用于太阳能电池的背板及其制法。
为了解决上述的技术问题,本发明所采用的其中一技术方案是,提供一种用于太阳能电池的背板。用于太阳能电池的背板包括一聚烯烃叠层结构和一保护层,保护层设置于聚烯烃叠层结构上。聚烯烃叠层结构包括一反射层以及设置于反射层上的一透光层;其中,透光层包括一连续相和分散于连续相中的一分散相,连续相是由聚烯烃所形成,分散相是由橡胶弹性体所形成,分散相在透光层中的含量为10重量百分比至25重量百分比。
优选地,以透光层的总重为基准,分散相在透光层中的含量为12重量百分比至24重量百分比,形成连续相的聚烯烃中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。
优选地,橡胶弹性体为乙烯-丙烯橡胶,且乙烯-丙烯橡胶中的乙烯含量为25重量百分比至55重量百分比。
优选地,形成反射层的材料为聚烯烃,反射层和透光层是以共挤出方式一体成型。
优选地,以反射层的总重为基准,形成反射层的材料中包括30重量百分比至60重量百分比的聚丙烯以及40重量百分比至70重量百分比的聚乙烯。
优选地,以反射层的总重为基准,反射层包括10重量百分比至35重量百分比的反射填料。
优选地,保护层的厚度为15微米至25微米。
优选地,形成保护层的材料包括含氟聚合物,含氟聚合物包括聚偏二氟乙烯、聚四氟乙烯、乙烯-四氟乙烯共聚物、聚三氟氯乙烯以及乙烯-聚三氟氯乙烯共聚物中的一种或两种以上的组合。
优选地,保护层与透光层接触。
为了解决上述的技术问题,本发明所采用的另外一技术方案是,提供一种用于太阳能电池的背板的制法。用于太阳能电池的背板的制法包括以下步骤:提供一聚烯烃叠层结构,聚烯烃叠层结构包括相互堆叠设置的一反射层和一透光层,透光层包括一连续相和一分散相,连续相是由聚烯烃所形成,分散相的是由橡胶弹性体所形成,分散相在透光层中的含量为10重量百分比至25重量百分比。于聚烯烃叠层结构上涂布形成一保护层。
优选地,反射层和透光层是以共挤出方式一体成型。
优选地,保护层是以涂布方式形成于聚烯烃叠层结构上。
本发明的其中一有益效果在于,本发明所提供的用于太阳能电池的背板及其制法,其能通过“透光层包括一连续相和分散于连续相中的一分散相,分散相是由橡胶弹性体所形成,且分散相在透光层中的含量为10重量百分比至25重量百分比”的技术手段,以提升背板的耐候性、耐热性、阻隔性和耐冲击性。
为使能更进一步了解本发明的特征及技术内容,请参阅以下有关本发明的详细说明与附图,然而所提供的附图仅用于提供参考与说明,并非用来对本发明加以限制。
附图说明
图1为太阳能电池模块的立体分解示意图。
图2为本发明的用于太阳能电池的背板的侧视示意图。
图3为本发明的用于太阳能电池的背板的制法的步骤流程图。
图4为本发明的透光层的微观结构的侧视示意图。
具体实施方式
以下是通过特定的具体实例来说明本发明所公开有关“用于太阳能电池的背板及其制法”的实施方式,本领域技术人员可由本说明书所公开的内容了解本发明的优点与效果。本发明可通过其他不同的具体实施例加以施行或应用,本说明书中的各项细节也可基于不同观点与应用,在不悖离本发明的构思下进行各种修改与变更。另外,本发明的附图仅为简单示意说明,并非依实际尺寸的描绘,事先声明。以下的实施方式将进一步详细说明本发明的相关技术内容,但所公开的内容并非用以限制本发明的保护范围。
应当可以理解的是,本文中所使用的术语“或”,应视实际情况可能包括相关联的列出项目中的任一个或者多个的组合。
为了提供可应用于太阳能电池模块,且具备良好耐候性、耐热性、阻隔性和耐冲击性的背板,本发明提供了一种用于太阳能电池的背板及其制法。本发明用于太阳能电池的背板的制法可排除黏着剂的使用,进而解决以往使用黏着剂所会衍生的问题;并且,省略了复合加工的步骤后,便可降低背板的生产成本。
首先,请参阅图1所示,图1为太阳能电池模块的立体分解示意图。太阳能电池模块主要是由一玻璃盖板G、一乙烯-醋酸乙烯共聚物(EVA)层F、一太阳能电池S、另一乙烯-醋酸乙烯共聚物层F以及一背板B所组成。
市面上的太阳能电池种类繁多,本发明的背板B可适用于各种太阳能电池S,例如:硅晶型太阳能电池或薄膜型太阳能电池,但是本发明不以上述所举例的为限。太阳能电池S相对两侧的两个乙烯-醋酸乙烯共聚物层F是作为封装材料,可完整包覆于太阳能电池S外,并达到保护太阳能电池S的效果。另外,玻璃盖板G设置于太阳能电池S主要接收光线的一侧,玻璃盖板G的作用为防止环境中的物质与太阳能电池S接触,而影响太阳能电池S的光转换效率。背板B设置在太阳能电池S相对于玻璃盖板G的另一侧,关于本发明提供的背板B的结构,将于后进一步详述。
请合并参阅图2和图3所示,图2为本发明的用于太阳能电池的背板的侧视示意图,图3为本发明的用于太阳能电池的背板的制法的步骤流程图。于本实施例中,背板B包括一聚烯烃叠层结构1和一保护层2。保护层2设置于聚烯烃叠层结构1上,以达到保护聚烯烃叠层结构1的效果。
在制备用于太阳能电池的背板的制造方法中,首先,提供一聚烯烃叠层结构1(步骤S100)。聚烯烃叠层结构1具有良好的光反射效果,可使散射的光线反射至太阳能电池S,以提升太阳能电池模块中太阳能电池S的光利用率和光转换效率;并且,聚烯烃叠层结构1具有良好的耐候性、耐热性、阻隔性和耐冲击性,可避免外在环境因素(如温度或湿度)影响太阳能电池S的效能,并可防止太阳能电池S与外界物质接触造成磨损,以达到保护太阳能电池S的效果。保护层2具有良好的抗侵蚀效果,可保护太阳能电池S以及聚烯烃叠层结构1不受外界环境的侵蚀。
值得注意的是,本发明的聚烯烃叠层结构1是以共挤出(co-extrusion)方式形成,过程中不需涂布黏胶或设置黏着层。另一方面,本发明的保护层2是以涂布(coating)方式形成于聚烯烃叠层结构1上,过程中同样不需添加黏着剂。由此可知,本发明的背板B免除了黏着剂的使用,也省略了复合加工的步骤,具有生产成本较低的优点,并可克服以往会因水气渗入,导致黏着剂的黏性降低的问题。
具体来说,本发明的聚烯烃叠层结构1包括一反射层11和一透光层12,透光层12设置于反射层11上。反射层11和透光层12可通过共挤出的方式于相同的工艺步骤中制备而得,也就是说,反射层11和透光层12可以是一体成型。由于本发明的反射层11和透光层12是一体成型,故反射层11和透光层12之间具有较佳的密着性,如此一来,本发明的聚烯烃叠层结构1较不会有水气渗入,而导致反射层11或透光层12剥落的问题。并且,相较于聚酯材料而言,聚烯烃的材料本身就具有较佳的耐水性。
于本实施例中,反射层11的材料和透光层12的材料都是聚烯烃,因此,在共挤出过程时,不需另外于形成反射层11的材料或是形成透光层12的材料中添加架桥剂,通过热压的方式即可结合。然而,上述制备聚烯烃叠层结构1的方式仅为说明,本发明并非以上述为限。
聚烯烃叠层结构1中的反射层11,可反射未被太阳能电池S所接收的散射光线回太阳能电池S,以提升太阳能电池S的光利用率和光转换效率。于本实施例中,以反射层11的总重为基准,形成反射层11的材料中包括30重量百分比至60重量百分比的聚丙烯以及40重量百分比至70重量百分比的聚乙烯。
具体来说,本发明的聚丙烯可以是均聚聚丙烯(polypropylene homopolymer,简称PP-H)、嵌段共聚聚丙烯(polypropylene block copolymer,简称PP-B)或无规共聚聚丙烯(polypropylene random copolymer,简称PP-B)中的至少一种。于一较佳实施例中,形成反射层11的材料中的聚丙烯为均聚聚丙烯。
具体来说,聚乙烯可以是乙烯均聚物、乙烯共聚物或其混合物。乙烯均聚物是指仅使用乙烯作为单体所聚合而成的聚合物,乙烯共聚物是指由乙烯和另一种或多种单体共同聚合而成的共聚物。另外,聚乙烯可另区分为高密度聚乙烯(high density polyethylene,简称HDPE)、低密度聚乙烯(low density polyethylene,简称LDPE)、线性低密度聚乙烯(linear low density polyethylene,简称LLDPE)或茂金属聚乙烯(metallocenepolyethylene,简称mPE),但不以此为限。于一较佳实施例中,形成反射层11的材料中的聚乙烯是选用线性聚乙烯。
并且,为了提升反射层11的光反射效果,反射层11中可还包括10重量百分比至35重量百分比的反射填料。反射填料可以为二氧化钛、蒙托土(Montmorillonite,MMT)、二氧化硅、铝银浆(Aluminiumpaste)、云母粉(Mica powder)、硫酸钡或碳酸钙,但不以此为限。于一较佳实施例中,选用二氧化钛作为反射填料,二氧化钛不仅可提高太阳能电池模块的光转换效率,还可提升反射层11的耐候性,进而提升太阳能电池模块的使用寿命。
聚烯烃叠层结构1中的透光层12,具有良好的耐候性、耐热性、阻隔性和耐冲击性,可达到保护太阳能电池S的效果,并可延长太阳能电池模块的使用寿命。于本实施例中,以透光层12的总重为基准,形成透光层12的材料中包括60重量百分比至80重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。其中,聚丙烯中掺混了20重量百分比至30重量百分比的橡胶弹性体,换句话说,若以透光层12的总重为基准,橡胶弹性体的含量为12重量百分比至24重量百分比,然而,本发明不以上述为限。较佳的,在透光层12中橡胶弹性体的含量为10重量百分比至25重量百分比。更佳的,在透光层12中橡胶弹性体的含量为20重量百分比至25重量百分比。通过橡胶弹性体的添加,可提升透光层12的刚性,以达到与以往聚酯薄膜相近的物理特性。
具体来说,橡胶弹性体可以是以乙烯或丙烯作为基础,并在乙烯(或丙烯)的聚合过程中添加丙烯(或乙烯)、丁烯或辛烯等单体,以合成出聚烯烃弹性体(Polyolefinelastomer,POE);或者,橡胶弹性体可以是将聚乙烯、聚丙烯和其他烯烃系材料(例如但不限于:二元乙丙橡胶或三元乙丙橡胶)共混,所形成的热塑性烯烃弹性体(Thermoplasticolefin elastomer,TPO)。
于一较佳实施例中,形成透光层12的材料中的聚丙烯为嵌段共聚聚丙烯,形成透光层12的材料中的聚乙烯是选用线性聚乙烯,且透光层12中的橡胶弹性体为乙烯-丙烯橡胶。在乙烯-丙烯橡胶中,乙烯和丙烯的含量可在合成时进行调整。较佳的,乙烯-丙烯橡胶中的乙烯含量为25重量百分比至55重量百分比。更佳的,乙烯-丙烯橡胶中的乙烯含量为30重量百分比至50重量百分比。当乙烯的含量低于25重量百分比或是高于55重量百分比时,透光层12无法具有良好的抗冲击性。
另请参阅图4所示,就微观结构而言,本发明的透光层12中包括一连续相121和一分散相122,分散相122均匀的分散于连续相121中。
在本发明中,形成连续相121的材料为聚烯烃,即连续相121是由前述聚乙烯和聚丙烯所形成。通过调控聚乙烯和聚丙烯的含量比,可使透光层12具有可媲美以往聚酯薄膜的硬度和机械强度。具体来说,若以透光层12的总重为基准,形成连续相121的材料中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。另一方面,形成分散相122的材料为橡胶弹性体,即分散相122是由乙烯-丙烯橡胶所形成。通过橡胶弹性体的添加,可提升透光层12的耐冲击性。
本发明通过调控分散相122在透光层12中的含量,可使透光层12具有良好的成膜性和耐冲击性。若分散相122在透光层12中的比例过高,则会降低透光层12的成膜性以及黏着性,进而影响背板B的特性;若分散相122在透光层12中的比例过低,则透光层12无法具备足够的耐热性和耐冲击性。
请再合并参阅图2和图3所示,在制备用于太阳能电池的背板的制造方法中,于聚烯烃叠层结构1上形成一保护层2(步骤S102)。保护层2设置于聚烯烃叠层结构1上,保护层2可选择与反射层11接触或是与透光层12接触。于本实施例中,保护层2设置于聚烯烃叠层结构1上,并与透光层12接触。如此一来,当背板B应用于太阳能电池模块时,未被太阳能电池S所接收的光线可通过较短的光程被反射层11反射,以降低光线能量的损失,进而提升太阳能电池模块的光转换效率。然而,本发明不以此为限。
为了提升保护层2抵抗外界环境侵蚀的效果,保护层2的材料中包括一含氟聚合物,含氟聚合物包括聚偏二氟乙烯(polyvinylidene difluoride,简称PVDF)、聚四氟乙烯(polytetrafluoroethylene,简称PTFE)、乙烯-四氟乙烯共聚物(polyethylenetetrafluoroethylene,简称ETFE)、聚三氟氯乙烯(polychlorotrifluoroethene,简称PCTFE)以及乙烯-聚三氟氯乙烯共聚物(polyethylene chlorotrifluoroethene,简称ECTFE)之中的一种或两种以上的组合。于一较佳实施例中,含氟聚合物为乙烯-四氟乙烯共聚物,且保护层2的厚度为15微米至25微米。
[实施例的有益效果]
本发明的其中一有益效果在于,本发明所提供的用于太阳能电池的背板及其制法,其能通过“透光层12包括一连续相121和分散于连续相121中的一分散相122”、“连续相121是由聚烯烃所形成,分散相122是由橡胶弹性体所形成”以及“分散相在所述透光层12中的含量为10重量百分比至25重量百分比”的技术特征,以提升背板B的耐候性、耐热性、阻隔性和耐冲击性。
更进一步来说,本发明所提供的用于太阳能电池的背板及其制法,其能通过“反射层11和透光层12是以共挤出方式一体成型”以及“保护层2是以涂布方式形成于聚烯烃叠层结构1上”的技术特征,排除黏着剂的使用,以降低生产成本以及产品的不良率,并可避免长时间使用后黏着剂老化,或因水气渗入降低黏着剂黏性所衍生的问题。
更进一步来说,本发明所提供的用于太阳能电池的背板及其制法,其能通过“连续相的材料中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯”或“乙烯-丙烯橡胶中的乙烯含量为25重量百分比至55重量百分比”的技术特征,以使透光层12可具有与传统聚酯薄膜相近的硬度特性,并可具有一定的阻隔性和耐冲击性。
更进一步来说,本发明所提供的用于太阳能电池的背板及其制法,其能通过“所述反射层包括10重量百分比至35重量百分比的反射填料”的技术特征,可提升反射层11的反射效果,以将散射的光线反射至太阳能电池S,进而提升太阳能电池模块的光转换效率。
更进一步来说,本发明所提供的用于太阳能电池的背板及其制法,其能通过“所述保护层2与所述透光层12接触”的技术特征,以缩短未被太阳能电池S接收的光线被反射层11所反射的光程,并降低光线的能量损失,进而提升太阳能电池模块的光转换效率。
以上所公开的内容仅为本发明的优选可行实施例,并非因此局限本发明的权利要求书的保护范围,所以凡是运用本发明说明书及附图内容所做的等效技术变化,均包含于本发明的权利要求书的保护范围内。
Claims (12)
1.一种用于太阳能电池的背板,其特征在于,所述用于太阳能电池的背板包括:
一聚烯烃叠层结构,其包括一反射层以及设置于所述反射层上的一透光层;其中,所述透光层包括一连续相和分散于所述连续相中的一分散相,所述连续相是由聚烯烃所形成,所述分散相是由橡胶弹性体所形成,所述分散相在所述透光层中的含量为10重量百分比至25重量百分比;以及
一保护层,其设置于所述聚烯烃叠层结构上。
2.根据权利要求1所述的用于太阳能电池的背板,其特征在于,以所述透光层的总重为基准,所述分散相在所述透光层中的含量为12重量百分比至24重量百分比,形成所述连续相的聚烯烃中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。
3.根据权利要求1所述的用于太阳能电池的背板,其特征在于,所述橡胶弹性体为乙烯-丙烯橡胶,且所述乙烯-丙烯橡胶中的乙烯含量为25重量百分比至55重量百分比。
4.根据权利要求1所述的用于太阳能电池的背板,其特征在于,形成所述反射层的材料为聚烯烃,所述反射层和所述透光层是以共挤出方式一体成型。
5.根据权利要求1所述的用于太阳能电池的背板,其特征在于,以所述反射层的总重为基准,形成所述反射层的材料中包括30重量百分比至60重量百分比的聚丙烯以及40重量百分比至70重量百分比的聚乙烯。
6.根据权利要求1所述的用于太阳能电池的背板,其特征在于,以所述反射层的总重为基准,所述反射层包括10重量百分比至35重量百分比的反射填料。
7.根据权利要求1所述的用于太阳能电池的背板,其特征在于,所述保护层的厚度为15微米至25微米。
8.根据权利要求1所述的用于太阳能电池的背板,其特征在于,形成所述保护层的材料包括含氟聚合物,所述含氟聚合物包括聚偏二氟乙烯、聚四氟乙烯、乙烯-四氟乙烯共聚物、聚三氟氯乙烯以及乙烯-聚三氟氯乙烯共聚物中的一种或两种以上的组合。
9.根据权利要求1所述的用于太阳能电池的背板,其特征在于,所述保护层与所述透光层接触。
10.一种用于太阳能电池的背板的制法,其特征在于,所述用于太阳能电池的背板的制法包括:
提供一聚烯烃叠层结构;其中,所述聚烯烃叠层结构包括相互堆叠设置的一反射层和一透光层,所述透光层包括一连续相和一分散相,所述连续相是由聚烯烃所形成,所述分散相是由橡胶弹性体所形成,所述分散相在所述透光层中的含量为10重量百分比至25重量百分比;以及
于所述聚烯烃叠层结构上形成一保护层。
11.根据权利要求10所述的用于太阳能电池的背板的制法,其特征在于,所述反射层和所述透光层是以共挤出方式一体成型。
12.根据权利要求10所述的用于太阳能电池的背板的制法,其特征在于,所述保护层是以涂布方式形成于所述聚烯烃叠层结构上。
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CN106229366A (zh) * | 2016-08-24 | 2016-12-14 | 苏州中来光伏新材股份有限公司 | 一种新型太阳能电池背板及其组件和制备方法 |
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CN106229366A (zh) * | 2016-08-24 | 2016-12-14 | 苏州中来光伏新材股份有限公司 | 一种新型太阳能电池背板及其组件和制备方法 |
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