CN114649434A - 图案化胶膜和光伏组件 - Google Patents

图案化胶膜和光伏组件 Download PDF

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CN114649434A
CN114649434A CN202011522327.7A CN202011522327A CN114649434A CN 114649434 A CN114649434 A CN 114649434A CN 202011522327 A CN202011522327 A CN 202011522327A CN 114649434 A CN114649434 A CN 114649434A
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adhesive film
patterned
bottom adhesive
acrylate
coating
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邓伟
杨楚峰
吴倩
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Hangzhou First Applied Material Co Ltd
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Hangzhou First Applied Material Co Ltd
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Priority to CN202011522327.7A priority Critical patent/CN114649434A/zh
Priority to EP21908442.3A priority patent/EP4207315A1/en
Priority to PCT/CN2021/093105 priority patent/WO2022134431A1/zh
Priority to US18/039,723 priority patent/US20240030361A1/en
Publication of CN114649434A publication Critical patent/CN114649434A/zh
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    • H01L31/0216Coatings
    • H01L31/02161Coatings for devices characterised by at least one potential jump barrier or surface barrier
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Abstract

本发明提供了一种图案化胶膜和光伏组件。该图案化胶膜包括底层胶膜和设置于底层胶膜表面的图案化涂层,底层胶膜在100℃下的最小力矩值M为0.2~2.5dN·m,图案化涂层的断裂伸长率≥20%。本申请的图案化胶膜中的图案化涂层的断裂伸长率≥20%,底层胶膜在100℃下的最小力矩值ML≥0.2dN·m,因而将包括该图案化胶膜的光伏组件进行层压时,由于底层胶膜具有相对较低的流动性,而图案化涂层的断裂伸长率可以与较低流动性的底层胶膜进行匹配,从而使得图案化胶膜在光伏组件层压过程中不会出现开裂的问题。

Description

图案化胶膜和光伏组件
技术领域
本发明涉及光伏组件技术领域,具体而言,涉及一种图案化胶膜和光伏组件。
背景技术
随着光伏平价上网时代的到来,不断提高光伏组件的发电效率成为行业的共识,电池片方面的技术创新有双面电池、半片电池、叠片电池等,封装材料方面的创新有白色胶膜、图案化透明背板、图案化玻璃等,其中双面电池可以与半片、叠片等形式复合使用,以尽可能提高电池片的发电功率,因此双面电池成为光伏行业主流的发展方向。常规的封装材料无法与双面电池完美匹配,组件间隙处存在封装损失,而图案化胶膜能很好的解决这个问题。
但是图案化涂层的拉伸性能比胶膜要差,层压过程中,由于胶膜流动很容易造成图案化涂层开裂。
发明内容
本发明的主要目的在于提供一种图案化胶膜和光伏组件,以解决现有技术中的图案化胶膜在光伏组件层压过程中出现开裂的问题。
为了实现上述目的,根据本发明的一个方面,提供了一种图案化胶膜,该图案化胶膜包括底层胶膜和设置于底层胶膜表面的图案化涂层,底层胶膜在100℃下的最小力矩值M为0.2~2.5dN·m,图案化涂层的断裂伸长率≥20%。
进一步地,上述底层胶膜在100℃下的最小力矩值M为0.4~2.0dN·m,进一步地,优选为0.6~1.5dN·m。
进一步地,上述底层胶膜为乙烯-醋酸乙烯共聚物和/或辛烯-聚烯烃得到的单层或多层胶膜,优选底层胶膜为乙烯-醋酸乙烯共聚物交联形成的胶膜时,底层胶膜的预交联度为5~60%,优选底层胶膜为辛烯-聚烯烃交联形成的胶膜时,底层胶膜的预交联度为1~50%,优选底层胶膜为乙烯-醋酸乙烯共聚物和辛烯-聚烯烃混合交联形成的胶膜时,底层胶膜的预交联度为1~50%。
进一步地,上述图案化涂层的断裂伸长率≥30%,进一步地,优选图案化涂层的断裂伸长率≥40%。
进一步地,上述底层胶膜与图案化涂层之间的粘结力≥30N/cm,优选底层胶膜与图案化涂层之间的粘结力≥40N/cm,进一步地,优选底层胶膜与图案化涂层之间的粘结力≥50N/cm。
进一步地,上述图案化涂层由涂料组合物经固化而成,以质量百分比计,该涂料组合物包括:20~60%的UV树脂、10~30%的稀释单体、0.5~5%的光引发剂、20~50%的钛白粉以及1~5%的助剂,优选UV树脂的伸展率≥100%;优选UV树脂选自聚氨酯丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的任意一种或多种;优选聚氨酯丙烯酸酯选自CN8881NS、CN8887NS、CN8888NS、CN9001 NS、CN9021、CN966J75 NS、6148J-75、DR-U299、DR-U384中的任意一种或多种,优选聚酯丙烯酸酯选自CN704、CN710、CN3108 NS、DR-E524中的任意一种或多种,优选纯丙烯酸酯选自6584N-1、DR-A845、DR-A822中的任意一种或多种;优选稀释单体是指含C=C双键的有机物,优选稀释单体的分子量为100~1000,优选稀释单体选自(甲基)丙烯酸酯、乙烯基醚中的任意一种或多种;优选光引发剂为紫外光引发剂,优选紫外光引发剂选自光引发剂TPO、光引发剂184、光引发剂1173、光引发剂TPO-L中的任意一种或多种;优选助剂选自分散剂、消泡剂、流平剂中的任意一种或多种,优选分散剂选自阴离子型分散剂、高分子型分散剂中的任意一种或多种,优选消泡剂选自丙烯酸酯类消泡剂、有机硅类消泡剂中的任意一种或多种,优选流平剂选自丙烯酸酯类流平剂、氟碳类流平剂中的任意一种或多种。
进一步地,UV树脂与稀释单体的质量比为1:1~5:1。
进一步地,上述图案化涂层的外围尺寸与光伏组件的大小相一致,图案化涂层的网格镂空区域与光伏组件铺设的电池片形状相一致,优选图案化涂层的厚度为10~100μm,优选为20~100μm。
进一步地,上述底层胶膜为多层共挤膜,优选底层胶膜的厚度为300~1000μm。
在本申请的另一种典型的实施方式中,提供了一种光伏组件,该光伏组件包括依次叠置的第一玻璃层、透明胶膜、电池片、光伏胶膜、第二玻璃层或光伏背板,光伏胶膜为前述的图案化胶膜,图案化胶膜的图案化涂层的网格镂空区域与电池片一一对应设置。
应用本发明的技术方案,本申请的图案化胶膜中的图案化涂层的断裂伸长率≥20%,底层胶膜在100℃下的最小力矩值ML≥0.2dN·m,因而将包括该图案化胶膜的光伏组件进行层压时,由于底层胶膜具有相对较低的流动性,而图案化涂层的断裂伸长率可以与较低流动性的底层胶膜进行匹配,从而使得图案化胶膜在光伏组件层压过程中不会出现开裂的问题。
具体实施方式
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。下面将结合实施例来详细说明本发明。
如背景技术所分析的,现有技术中存在图案化胶膜在光伏组件层压过程中出现开裂的问题,为解决该问题,本发明提供了一种图案化胶膜和光伏组件。
在本申请的一种典型的实施方式中,提供了一种图案化胶膜,该图案化胶膜包括底层胶膜和设置于底层胶膜表面的图案化涂层,底层胶膜在100℃下的最小力矩值M为0.2~2.5dN·m,图案化涂层的断裂伸长率≥20%。
本申请的图案化胶膜中的图案化涂层的断裂伸长率≥20%,底层胶膜在100℃下的最小力矩值ML≥0.2dN·m,因而将包括该图案化胶膜的光伏组件进行层压时,由于底层胶膜具有相对较低的流动性,而图案化涂层的断裂伸长率可以与较低流动性的底层胶膜进行匹配,从而使得图案化胶膜在光伏组件层压过程中不会出现开裂的问题。
为进一步地减小底层胶膜的流动性,从而使其更易于和图案化涂层相匹配,进而尽可能的降低图案化胶膜在光伏组件层压过程中出现开裂的几率,优选上述底层胶膜在100℃下的最小力矩值M为0.4~2.0dN·m,进一步地,优选为0.6~1.5dN·m。
为更易于控制底层胶膜的力矩值M,从而控制其流动性,优选上述底层胶膜为乙烯-醋酸乙烯共聚物和/或辛烯-聚烯烃得到的单层或多层胶膜,优选底层胶膜为乙烯-醋酸乙烯共聚物交联形成的胶膜时,底层胶膜的预交联度为5~60%,优选底层胶膜为辛烯-聚烯烃交联形成的胶膜时,底层胶膜的预交联度为1~50%,优选底层胶膜为乙烯-醋酸乙烯共聚物和辛烯-聚烯烃混合交联形成的胶膜时,底层胶膜的预交联度为1~50%。
为更好的使图案化涂层的断裂伸长率与底层胶膜的流动性起到相互协同的作用,优选上述图案化涂层的断裂伸长率≥30%,进一步地,优选图案化涂层的断裂伸长率≥40%。
为提高底层胶膜与图案化涂层之间的结合强度,从而尽可能地避免层压过程中底层胶膜与图案化涂层出现错位的问题,优选上述底层胶膜与图案化涂层之间的粘结力≥30N/cm,优选底层胶膜与图案化涂层之间的粘结力≥40N/cm,进一步地,优选底层胶膜与图案化涂层之间的粘结力≥50N/cm。
在本申请的一种实施例中,上述图案化涂层由涂料组合物经固化而成,以质量百分比计,该涂料组合物包括:20~60%的UV树脂、10~30%的稀释单体、0.5~5%的光引发剂、20~50%的钛白粉以及1~5%的助剂;优选UV树脂选自聚氨酯丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的任意一种或多种;优选聚氨酯丙烯酸酯选自CN8881NS、CN8887NS、CN8888NS、CN9001 NS、CN9021、CN966J75 NS、6148J-75、DR-U299、DR-U384中的任意一种或多种,优选聚酯丙烯酸酯选自CN704、CN710、CN3108 NS、DR-E524中的任意一种或多种,优选纯丙烯酸酯选自6584N-1、DR-A845、DR-A822中的任意一种或多种;优选稀释单体是指含C=C双键的有机物,优选稀释单体的分子量为100~1000,优选稀释单体选自(甲基)丙烯酸酯、乙烯基醚中的任意一种或多种;优选光引发剂为紫外光引发剂,优选紫外光引发剂选自光引发剂TPO、光引发剂184、光引发剂1173、光引发剂TPO-L中的任意一种或多种;优选助剂选自分散剂、消泡剂、流平剂中的任意一种或多种,优选分散剂选自阴离子型分散剂、高分子型分散剂中的任意一种或多种,优选消泡剂选自丙烯酸酯类消泡剂、有机硅类消泡剂中的任意一种或多种,优选流平剂选自丙烯酸酯类流平剂、氟碳类流平剂中的任意一种或多种。
具有高延展率的上述UV树脂配合以上具有优良柔韧性的稀释单体以及优选的光引发剂、钛白粉以及助剂,在综合各组分用量类别和用量多少的基础上,更有助于各组分之间的协同,从而得到断裂伸长率优良的图案化涂层。
为提高UV树脂与稀释单体之间的聚合效果,从而得到性能更优良的图案化涂层,优选上述UV树脂与稀释单体的质量比为1:1~5:1。
为更好的与底层胶膜相匹配,优选上述图案化涂层的外围尺寸与光伏组件的大小相一致,图案化涂层的网格镂空区域与光伏组件铺设的电池片形状相一致,优选图案化涂层的厚度为10~100μm,优选为20~100μm。
为更好的与光伏组件中的电池片之间的间隙相匹配,优选上述底层胶膜为多层共挤膜,优选底层胶膜的厚度为300~1000μm。
在本申请的另一种典型的实施方式中,提供了一种光伏组件,该光伏组件包括依次叠置的第一玻璃层、透明胶膜、电池片、光伏胶膜、第二玻璃层或光伏背板,光伏胶膜为上述的图案化胶膜,图案化胶膜的图案化涂层的网格镂空区域与电池片一一对应设置。
以下将结合具体实施例和对比例,对本申请的有益效果进行说明。
实施例1
涂料组合物包括:60份CN8881 NS、5份丙烯酸异冰片酯、5份新戊二醇二丙烯酸酯、0.5份光引发剂184、27.5份钛白粉、1份BYK-110和1份BYK-1790。
将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为45%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为1.5dN·m,再将上述的涂料组合物混合均匀后印刷到底层胶膜上,得到20μm厚的图案化涂层,图案化涂层的断裂伸长率为50%,最终得到图案化胶膜。
实施例2
实施例2与实施例1的区别在于,涂料组合物包括:40份CN966J75 NS、20份丙烯酸异冰片酯、10份新戊二醇二丙烯酸酯、2份184、27份钛白粉、0.5份BYK-111和0.5份BYK-065,最终得到图案化胶膜,图案化涂层的断裂伸长率为40%。
实施例3
实施例3与实施例1的区别在于,涂料组合物包括:30份CN704、10份丙烯酸异冰片酯、10份新戊二醇二丙烯酸酯、5份184、40份钛白粉、3份BYK-110和2份BYK-354,最终得到图案化胶膜,图案化涂层的断裂伸长率为30%。
实施例4
实施例4与实施例1的区别在于,涂料组合物包括:20份6584N-1、15份丙烯酸异冰片酯、10份新戊二醇二丙烯酸酯、1份184、50份钛白粉、3份BYK-111和1份BYK-052,最终得到图案化胶膜,图案化涂层的断裂伸长率为20%。
实施例5
实施例5与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为15%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为0.6dN·m,最终得到图案化胶膜。
实施例6
实施例6与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为30%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为1.0dN·m,最终得到图案化胶膜。
实施例7
实施例7与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为10%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为0.4dN·m,最终得到图案化胶膜。
实施例8
实施例8与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为55%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为2.0dN·m,最终得到图案化胶膜。
实施例9
实施例9与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为5%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为0.2dN·m,最终得到图案化胶膜。
实施例10
实施例10与实施例1的区别在于,将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为60%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为2.5dN·m,最终得到图案化胶膜。
实施例11
实施例11与实施例1的区别在于,UV树脂与稀释单体的质量比为1:1,最终得到图案化胶膜。
实施例12
实施例12与实施例1的区别在于,UV树脂与稀释单体的质量比为3:1,最终得到图案化胶膜。
实施例13
实施例13与实施例1的区别在于,UV树脂与稀释单体的质量比为5:1,最终得到图案化胶膜。
实施例14
实施例14与实施例1的区别在于,底层胶膜的预交联度为25%,最终得到图案化胶膜。
实施例15
实施例15与实施例1的区别在于,底层胶膜的预交联度为40%,最终得到图案化胶膜。
实施例16
实施例16与实施例1的区别在于,底层胶膜的厚度为1000μm,图案化涂层的厚度为100μm,最终得到图案化胶膜。
实施例17
实施例17与实施例1的区别在于,底层胶膜的厚度为500μm,图案化涂层的厚度为10μm,最终得到图案化胶膜。
对比例1
对比例1与实施例1的区别在于,涂料组合物包括:60份CN UVE151 NS、5份丙烯酸异冰片酯、5份新戊二醇二丙烯酸酯、1份184、27份钛白粉、1份BYK-110和1份BYK-1790。图案化涂层的断裂伸长率为15%,最终得到图案化胶膜。
对比例2
对比例2与实施例1的区别在于,
将乙烯-醋酸乙烯共聚物通过挤出流延,得到多层的、300μm厚的底层胶膜,并对该底层胶膜进行电子束辐照,得到预交联度为2%的底层胶膜,并用硫化仪(台湾优肯2010SD)测试100℃下底层胶膜的ML值为0.1dN·m,最终得到图案化胶膜。
通过GB/T13541-92测试标准分别测试实施例1至17、对比例1、对比例2制备得到的图案化胶膜中的图案化涂层的断裂伸长率。
通过GB/T 2790测试标准分别测试实施例1至17、对比例1、对比例2制备得到的任一种图案化胶膜的底层胶膜与图案化涂层之间的粘结力(记为A),并将测试结果列于表1。
性能测试:
按照玻璃、透明胶膜、电池片、实施例1至17、对比例1、对比例2制备得到的任一种图案化胶膜、玻璃的顺序制作光伏组件,在150℃下层压18min,观察层压后图案化的开裂情况(记为B),并将测试结果列于表1。
表1
Figure BDA0002849416790000071
Figure BDA0002849416790000081
从以上的描述中,可以看出,本发明上述的实施例实现了如下技术效果:
本申请的图案化胶膜中的图案化涂层的断裂伸长率≥20%,底层胶膜在100℃下的最小力矩值ML≥0.2dN·m,因而将包括该图案化胶膜的光伏组件进行层压时,由于底层胶膜具有相对较低的流动性,而图案化涂层的断裂伸长率可以与较低流动性的底层胶膜进行匹配,从而使得图案化胶膜在光伏组件层压过程中不会出现开裂的问题。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。

Claims (10)

1.一种图案化胶膜,所述图案化胶膜包括底层胶膜和设置于所述底层胶膜表面的图案化涂层,其特征在于,所述底层胶膜在100℃下的最小力矩值M为0.2~2.5dN·m,所述图案化涂层的断裂伸长率≥20%。
2.根据权利要求1所述的图案化胶膜,其特征在于,所述底层胶膜在100℃下的最小力矩值M为0.4~2.0dN·m,进一步地,优选为0.6~1.5dN·m。
3.根据权利要求1或2所述的图案化胶膜,其特征在于,所述底层胶膜为乙烯-醋酸乙烯共聚物和/或辛烯-聚烯烃得到的单层或多层胶膜,优选所述底层胶膜为乙烯-醋酸乙烯共聚物交联形成的胶膜时,所述底层胶膜的预交联度为5~60%,优选所述底层胶膜为辛烯-聚烯烃交联形成的胶膜时,所述底层胶膜的预交联度为1~50%,优选所述底层胶膜为乙烯-醋酸乙烯共聚物和辛烯-聚烯烃混合交联形成的胶膜时,所述底层胶膜的预交联度为1~50%。
4.根据权利要求1至3中任一项所述的图案化胶膜,其特征在于,所述图案化涂层的断裂伸长率≥30%,进一步地,优选所述图案化涂层的断裂伸长率≥40%。
5.根据权利要求1至3中任一项所述的图案化胶膜,其特征在于,所述底层胶膜与所述图案化涂层之间的粘结力≥30N/cm,优选所述底层胶膜与所述图案化涂层之间的粘结力≥40N/cm,进一步地,优选所述底层胶膜与所述图案化涂层之间的粘结力≥50N/cm。
6.根据权利要求1至3中任一项所述的图案化胶膜,所述图案化涂层由涂料组合物经固化而成,其特征在于,以质量百分比计,所述涂料组合物包括:
20~60%的UV树脂;
10~30%的稀释单体;
0.5~5%的光引发剂;
20~50%的钛白粉;
以及1~5%的助剂,
优选所述UV树脂的伸展率≥100%;优选所述UV树脂选自聚氨酯丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的任意一种或多种;优选所述聚氨酯丙烯酸酯选自CN8881NS、CN8887NS、CN8888NS、CN9001 NS、CN9021、CN966J75 NS、6148J-75、DR-U299、DR-U384中的任意一种或多种,优选所述聚酯丙烯酸酯选自CN704、CN710、CN3108 NS、DR-E524中的任意一种或多种,优选所述纯丙烯酸酯选自6584N-1、DR-A845、DR-A822中的任意一种或多种;
优选所述稀释单体是指含C=C双键的有机物,优选所述稀释单体的分子量为100~1000,优选所述稀释单体选自(甲基)丙烯酸酯、乙烯基醚中的任意一种或多种;
优选所述光引发剂为紫外光引发剂,优选所述紫外光引发剂选自光引发剂TPO、光引发剂184、光引发剂1173、光引发剂TPO-L中的任意一种或多种;
优选助剂选自分散剂、消泡剂、流平剂中的任意一种或多种,优选所述分散剂选自阴离子型分散剂、高分子型分散剂中的任意一种或多种,优选所述消泡剂选自丙烯酸酯类消泡剂、有机硅类消泡剂中的任意一种或多种,优选所述流平剂选自丙烯酸酯类流平剂、氟碳类流平剂中的任意一种或多种。
7.根据权利要求6所述的图案化胶膜,其特征在于,所述UV树脂与所述稀释单体的质量比为1:1~5:1。
8.根据权利要求6所述的图案化胶膜,其特征在于,所述图案化涂层的外围尺寸与光伏组件的大小相一致,所述图案化涂层的网格镂空区域与所述光伏组件铺设的电池片形状相一致,优选所述图案化涂层的厚度为10~100μm,优选为20~100μm。
9.根据权利要求1至3中任一项所述的图案化胶膜,其特征在于,所述底层胶膜为多层共挤膜,优选所述底层胶膜的厚度为300~1000μm。
10.一种光伏组件,所述光伏组件包括依次叠置的第一玻璃层、透明胶膜、电池片、光伏胶膜、第二玻璃层或光伏背板,其特征在于,所述光伏胶膜为权利要求1至9中任一项所述的图案化胶膜,所述图案化胶膜的图案化涂层的网格镂空区域与所述电池片一一对应设置。
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