CN113314639A - 一种功能型背板的制备方法及功能型背板 - Google Patents
一种功能型背板的制备方法及功能型背板 Download PDFInfo
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Abstract
本发明涉及一种功能型背板的制备方法,功能型背板包括依次设置的网格涂层、内层膜、基层膜和外层膜,采用连续套印装置,制备方法为(a)将内层膜与基层膜复合后,在内层膜上用套印的方式印刷网格涂层,再与外层膜进行复合;或(b)在内层膜一面上用套印的方式印刷网格涂层,基层膜与外层膜复合,再将内层膜的另一面与基层膜复合;或(c)将内层膜依次与基层膜、外层膜复合后,在内层膜上用印刷网格涂层。本发明可以多次涂覆,增加涂层的厚度且保证网格涂层的外观,提高反射率,大大提升组件端的功率;可以进一步提升印刷速率;通过结构多样化的设计与工艺,可以最大减少材料端的损耗;降低整体背板的成本,具有较大产品附加值。
Description
技术领域
本发明涉及太阳能光伏组件技术领域,具体涉及一种功能型背板的制备方法及功能型背板。
背景技术
随着地球传统能源的日益减少,全球对新能源的需求越来越大,而太阳能作为新型能源,是人类可以利用的最丰富的能源,可以就地开发利用,不存在运输问题,因此能够实现能源光伏转化的产业化是全球备受关注的焦点。
在光伏发电领域,因双面组件具有度电成本优势,因此双面组件逐步扩展市场份额,结合双面电池技术,双面组件将成为高效组件的主力军,但是双面组件不同等于采取双玻的形式,透明背板的双面单玻组件已经有实际应用,透明背板双面单玻璃组件前景较好,具有产品轻质、安装方便、PID性能更优、提升组件产能等优势;此外网格的设计可以提升功率,避免内层UV等内层老化的可靠性,透明加上网格的设计可以增加二次反射,阻隔紫外损伤;担保玻璃减薄,持续维持组件重量轻质化优势,破损风险低。
但是现有技术中还存在如下的几个问题:1)随着光伏平价上网的优势,降本提质增效逐步成为本行业发展方向,光伏背板在行业内处于中上游,寻求高附加值产品,匹配行业发展需要逐步成为企业未来发展方向,因此技术工艺革新为导向的发展路线是大势所趋;2)透明白网格以及白色黑网格背板主要通过丝网印刷或者涂布线网纹辊涂布,效率以及功能性增益无法进一步提升;3)网格化背板制备工艺成品率低,损耗较大,特别是透明白网格背板成本较高,成品率低导致成本大大提升;4)现阶段双玻具有户外自爆异常多、生产良率低下、不易安装运输、单瓦工时长等局限性,根据电站的实际反馈,每兆瓦双玻组件支架钢材用量比常规多6吨,高重量的双玻电站需要使用大功率的追踪系统,增加耗电,同时双玻组件支架负担大,跟踪系统故障率超过20%这些都带来了更多的成本。
现有技术中常规丝网印刷涂覆存在生产效率慢,自动化程度低等问题,常规凹版印刷网格涂层,厚度受限,即使满足一定厚度,也会存在涂层厚度不均,表面外观深浅不一,以及边缘锯齿问题,影响发电效率,以上两种印刷方法都只能一次印刷成型,结构与工艺相对单一,成品率、生产效率以及厚度可控性相对较低。
因此,提高生产效率、降低成本是研究的重点,对背板及其工艺进行改进,使其能够提高生产效率、降低成本且带来更高的产品附加值。
发明内容
有鉴于此,本发明的目的是提供一种能够提高生产效率、降低成本且能带来更高的产品附加值的功能型背板的制备方法及功能型背板。
为达到上述目的,本发明采用的技术方案是:
本发明的第一个目的在于提供一种功能型背板的制备方法,所述功能型背板包括依次设置的网格涂层、内层膜、基层膜和外层膜,采用连续套印装置,所述制备方法为:
(a)将所述内层膜与所述基层膜复合后,在所述内层膜上用套印的方式印刷所述网格涂层,再与所述外层膜进行复合;
或(b)在所述内层膜一面上用套印的方式印刷所述网格涂层,所述基层膜与所述外层膜复合,再将所述内层膜的另一面与所述基层膜复合;
或(c)将所述内层膜依次与所述基层膜、所述外层膜复合后,在所述内层膜上用套印的方式印刷所述网格涂层。
具体的,所述内层膜为涂层或聚烯烃层,当所述内层膜为涂层时,所述涂层可以采用套印的方式印刷或采用常规涂布方式进行涂布。
优选地,所述网格涂层为白色网格涂层或黑色网格涂层,所述涂层和所述网格涂层为独立地选自氟碳涂层、聚酯型涂层、聚醚型涂层和丙烯酸型涂层中的一种或多种。
进一步优选地,所述内层膜为涂层、所述网格涂层为白色网格涂层时,所述涂层、所述基层膜和所述外层膜均为透明色,所述功能型背板还包括依次设置的所述涂层、所述白色网格涂层、所述基层膜和所述外层膜。
更进一步优选地,所述制备方法还包括方法(d),在所述基层膜的一面上用套印的方式印刷所述白色网格涂层,再于所述白色网格涂层上制备所述涂层后,所述基层膜的另一面再与所述外层膜进行复合。
更进一步优选地,当所述涂层的制备采用套印的方式印刷时,所述白色网格涂层的印刷与所述涂层的印刷在同一条印刷线通过套印完成。
优选地,所述功能型背板还包括设置在所述聚烯烃层和所述基层膜之间的第一胶黏剂层、设置在所述基层膜和所述外层膜之间的第二胶黏剂层。
进一步优选地,所述第一胶黏剂层的胶黏剂和所述第二胶黏剂层中的胶黏剂可以选用聚氨酯胶黏剂,所述聚氨酯胶黏剂可以为溶剂型或无溶剂型。
具体的,所述基层膜为选自聚对苯二甲酸乙二醇膜、聚对苯二甲酸丁二醇酯膜、聚烯烃膜、聚酰亚胺膜、聚酰胺膜和聚丙烯酸衍生物膜中的一种,所述外层膜为选自聚偏乙烯膜和聚四氟乙烯膜中的一种。
具体的,所述连续套印装置包括多个连续设置的印刷组件、设置在两个所述印刷组件之间的烘干组件,所述印刷组件包括印刷辊、与所述印刷辊配合的压辊、设置在所述印刷辊和所述压辊后的调节辊、设置在所述印刷辊和所述调节辊之间的精度控制器,所述烘干组件包括至少一个弯管结构。
本发明的第二个目的在于提供一种功能型背板,使用如上所述功能型背板的制备方法制备所得。
与现有技术相比,本发明采用套印的方式,解决了网格涂层厚度受限以及网格涂层表面外观不良的问题,通过多次薄层的涂覆,增加涂层的厚度且保证网格涂层的表面外观,从而可以提高反射率,提升组件端的功率;通过套印装置中的烘干组件的弯道结构,可以进一步提升印刷速率;此外通过功能型背板的结构多样化的设计与工艺的选择,可以最大减少材料端的损耗;本发明的制备方法,可以较大程度地降低整体背板的成本,具有较大产品附加值。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
附图1为本发明的套印装置的结构示意图。
附图中涉及的附图标记和组成部分说明:
1、印刷辊;2、压辊;3、调节辊;4、精度控制器。
具体实施方式
下面将通过具体实施方式对本发明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。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
现有技术中常规丝网印刷涂覆存在生产效率慢,自动化程度低等问题,常规凹版印刷网格涂层,厚度受限,即使满足一定厚度,也会存在涂层厚度不均,表面外观深浅不一,以及边缘锯齿问题,影响发电效率,以上两种印刷方法都只能一次印刷成型,结构与工艺相对单一,成品率、生产效率以及厚度可控性相对较低。本发明将凹版印刷中的套印方式应用于背板上网格涂层的印刷,从而能够控制网格涂层的厚度及保证背板网格涂层的外观,从而提高反射率。
因此本发明提供了一种功能型背板的制备方法,采用连续套印装置,如附图1所示,连续套印装置包括多个连续的印刷组件、设置在两个印刷组件之间的烘干组件(图中未示出),印刷组件包括印刷辊1、与印刷辊配合的压辊2、设置在印刷辊1和压辊2后的调节辊3、设置在印刷辊1和调节辊3之间的精度控制器4,烘干组件(图中未示出)包括至少一个弯管结构。本发明连续套印装置为常规套印的装置,市场上可以采购。但是为了能够适应本发明的功能型背板印刷过程的需要,我们对烘干组件做了一些优化的调整改动,主要是烘干组件(图中未示出)设置了至少一个弯管结构,弯管结构的设置可以增加烘道的长度,从而能够加快印刷涂料的挥发,加快印刷速率,提升组件端功率。此外,本发明还对涂料中溶剂进行了选型以及通过配方改进的方式来提高涂料固化效率,目的同样也是为了加快印刷速率。以上改进,可以使本发明的印刷生产速率最高可达100m/min。
功能型背板包括依次设置的网格涂层、内层膜、基层膜、第二胶黏剂层和外层膜。
网格涂层为白色网格涂层或黑色网格涂层。内层膜为涂层或聚烯烃层。涂层和网格涂层为独立地选自氟碳涂层、聚酯型涂层、聚醚型涂层和丙烯酸型涂层中的一种或多种。基层膜为选自聚对苯二甲酸乙二醇膜、聚对苯二甲酸丁二醇酯膜、聚烯烃膜、聚酰亚胺膜、聚酰胺膜和聚丙烯酸衍生物膜中的一种。第二胶黏剂层的胶黏剂选用聚氨酯胶黏剂,聚氨酯胶黏剂可以选用溶剂型或无溶剂型。外层膜为选自聚偏乙烯膜和聚四氟乙烯膜中的一种。当内层膜为聚烯烃层,功能型背板还包括设置在聚烯烃层和基层膜之间的第一胶黏剂层。第一胶黏剂层的胶黏剂选用聚氨酯胶黏剂,聚氨酯胶黏剂可以选用溶剂型或无溶剂型。上述第一胶黏剂层和第二胶黏剂层的胶黏剂,也可以选用其他类型的胶黏剂,只要能实现粘接且能满足功能型背板的性能要求即可。
当内层膜为涂层时,涂层可以可以选用常规涂布方式或采用套印的方法印刷。此处提及的常规涂布方式即为现有技术中的常规涂布方式。
根据以上对功能型背板的结构的讨论,功能型背板的制备方法为:
(a)将内层膜与基层膜复合后,在内层膜上用套印的方式印刷网格涂层,再与外层膜进行复合;
或(b)在内层膜一面上用套印的方式印刷网格涂层,基层膜与外层膜复合,再将内层膜的另一面与基层膜复合;
或(c)将内层膜依次与基层膜、外层膜复合后,在内层膜上用套印的方式印刷网格涂层。
尤其需要指出的是,当网格涂层为白色网格涂层、内层膜为涂层时,涂层、基层膜和外层膜均为透明色,此时网格涂层与涂层的两层的制备顺序可以互换,因此功能型背板的结构还包括依次设置的涂层、白色网格涂层、基层膜、第二胶黏剂层和外层膜。对应的功能型背板的制备方法还包括(d)在基层膜的一面上用套印的方式印刷白色网格涂层,再于白色网格涂层上制备涂层后,基层膜的另一面再与外层膜进行复合。
当涂层的制备采用套印的方式印刷时,白色网格涂层的印刷与涂层的印刷在同一条印刷线通过套印完成。
现有技术中的网格涂层的印刷工艺的成品率较低,一般在95%左右,远远低于常规背板和透明背板的成品率,生产损耗大,明显增加了网格背板,尤其是透明网格背板的生产制造成本。采用本发明上述四种印刷涂布方式,能够较大程度降低整体背板的成本。采用本发明的方法每层涂布的厚度较薄且能快速干燥从而外观良好,网格涂层的厚度可以通过调整涂布的层数来达到想要的厚度,使得成品背板的反射率较高,大大提升组件端功率。采用本申请的套印方式,能够解决现有技术的缺陷。当功能型背板的网格涂层为白色网格涂层,涂层、基层膜和外层膜均为透明色时,其功能型背板在380-1100nm下的反射率达到80%以上,大大提升了组件端的功率。
对所公开的实施例的上述说明,使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (10)
1.一种功能型背板的制备方法,所述功能型背板包括依次设置的网格涂层、内层膜、基层膜和外层膜,其特征在于,采用连续套印装置,所述制备方法为:
(a)将所述内层膜与所述基层膜复合后,在所述内层膜上用套印的方式印刷所述网格涂层,再与所述外层膜进行复合;
或(b)在所述内层膜一面上用套印的方式印刷所述网格涂层,所述基层膜与所述外层膜复合,再将所述内层膜的另一面与所述基层膜复合;
或(c)将所述内层膜依次与所述基层膜、所述外层膜复合后,在所述内层膜上用套印的方式印刷所述网格涂层。
2.根据权利要求1所述功能型背板的制备方法,其特征在于:所述内层膜为涂层或聚烯烃层,当所述内层膜为涂层时,所述涂层可以采用套印的方式印刷或采用常规涂布方式进行涂布。
3.根据权利要求2所述功能型背板的制备方法,其特征在于:所述网格涂层为白色网格涂层或黑色网格涂层,所述涂层和所述网格涂层为独立地选自氟碳涂层、聚酯型涂层、聚醚型涂层和丙烯酸型涂层中的一种或多种。
4.根据权利要求3所述功能型背板的制备方法,其特征在于:所述内层膜为涂层、所述网格涂层为白色网格涂层时,所述涂层、所述基层膜和所述外层膜均为透明色,所述功能型背板还包括依次设置的所述涂层、所述白色网格涂层、所述基层膜和所述外层膜。
5.根据权利要求4所述功能型背板的制备方法,其特征在于:所述制备方法还包括方法(d),在所述基层膜的一面上用套印的方式印刷所述白色网格涂层,再于所述白色网格涂层上制备所述涂层后,所述基层膜的另一面再与所述外层膜进行复合。
6.根据权利要求4所述功能型背板的制备方法,其特征在于:当所述涂层的制备采用套印的方式印刷时,所述白色网格涂层的印刷与所述涂层的印刷在同一条印刷线通过套印完成。
7.根据权利要求2所述功能型背板的制备方法,其特征在于:所述功能型背板还包括设置在所述聚烯烃层和所述基层膜之间的第一胶黏剂层、设置在所述基层膜和所述外层膜之间的第二胶黏剂层。
8.根据权利要求1所述功能型背板的制备方法,其特征在于:所述基层膜为选自聚对苯二甲酸乙二醇膜、聚对苯二甲酸丁二醇酯膜、聚烯烃膜、聚酰亚胺膜、聚酰胺膜和聚丙烯酸衍生物膜中的一种,所述外层膜为选自聚偏乙烯膜和聚四氟乙烯膜中的一种。
9.根据权利要求1所述功能型背板的制备方法,其特征在于:所述连续套印装置包括多个连续设置的印刷组件、设置在两个所述印刷组件之间的烘干组件,所述印刷组件包括印刷辊、与所述印刷辊配合的压辊、设置在所述印刷辊和所述压辊后的调节辊、设置在所述印刷辊和所述调节辊之间的精度控制器,所述烘干组件包括至少一个弯管结构。
10.一种功能型背板,其特征在于,使用如权利要求1-9中任一所述功能型背板的制备方法制备所得。
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