CN1418379A - 光电薄膜组件的制备方法 - Google Patents
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Abstract
本发明涉及一种制备光电薄膜型组件(1)的方法，该组件包括提供在载体材料(3)上的薄膜型太阳能电池系统(2)。薄膜型太阳能电池系统(2)的至少一表面上被封装材料复合体(4)包封。在有薄膜型太阳能电池系统(2)的表面上具有密封层(5)。在层压步骤中，将封装材料(4)以及薄膜型太阳能电池系统(2)与载体(3)彼此接触在一起，并在压力和高温下加压，形成复合件(1)形式的耐大气光电薄膜型组件。以简单易行的方法，制备了一种抗紫外光、水蒸气和耐大气影响的光电薄膜型组件。通过对载体材料，例如塑料膜或塑料膜复合物形式的载体材料的选择，可额外地使光电组件具有柔韧性。
Description
本发明涉及一种光电薄膜组件的制备方法，所述组件具有施加在载体材料上的薄膜型太阳能电池系统，必要时其两侧被封装材料复合体包封。
现有技术
光电组件的作用是由日光产生电能。能量是通过太阳能电池系统产生的，而所述系统最好由薄膜型太阳能电池制成。薄膜型太阳能电池可以由各种半导体系统形成，例如CIGS(铜-铟-镓-硒化物)，CTS(镉-碲化物-硫化物)，a-Si(无定形硅)等。
向诸如玻璃的刚性载体材料或诸如聚酰亚胺、钢带、金属箔等类的柔性载体材料上施加以这种薄型半导体。
薄膜型太阳能电池对环境，例如湿度、氧和紫外光的影响是灵敏的。但是，应对其进行保护以使其免遭机械损害，还需进行电绝缘。因此，需用封装材料包封薄膜型太阳能电池的两侧。封装材料的实例包括一层或多层玻璃层和/或塑料薄膜层。
主要由聚氟乙烯(PVF)和聚对苯二甲酸乙二酯(PETP)组成的膜复合材料由申请人销售，商标为ICOSOLAR，在WO-A1-94/29106公开的真空胺化法中用于制备光电组件。尽管采用该已知的方法制备了光电组件，所述组件的太阳能电池系统具有令人满意抗环境影响的能力，但是该方法本身的能耗较高，并且生产周期较长。
发明的描述
本发明的目的是提供一种光电组件的制备方法，所述方法的生产周期短，能耗低，并且可制备在室外使用的具有优异耐大气侵蚀性的光电组件。
根据本发明，提供了一种开始述及类型的方法，该方法的特征在于：在层压步骤中，将由保护层和密封层构成的封装材料复合体的材料带和薄膜-太阳能电池系统和其载体材料的其他材料带在层压区按下列方式彼此接触，即密封层贴着薄膜型太阳能电池系统，在高压和必要时升高温度下在叠层位置进行层压，以形成光电薄膜型组件用的复合件。
本发明方法的优选实施方案是从属权利要求的主题。借助附图和实施例描述本发明
现在借助图1-5的附图详细描述本发明的实施方案：
图1示出了按本发明方法制备的具有较高刚度的光电组件1的构造，由位于刚性载体材料3如玻璃上的薄膜型太阳能电池系统2和第二种封装材料4构成，所述载体材料同时起封装材料的作用。
封装材料4示于图1a中，由塑料密封层5和阻挡层9构成，阻挡层包括用于气相沉积无机氧化物层7的载体层6和大气防护层8。
图2示出了按本发明方法制备的柔性薄膜型组件10的构造。其柔性特征是通过柔性载体材料11体现的。
图3示出了生产刚性薄膜型组件1的装置12。
图4示出了生产柔性薄膜型组件10的装置20。
图5示出了几种带有SiOx涂层的载体膜的水蒸气渗透性，其中采用不同的塑料作为载体膜，并对其进行了对比。
本发明的实施方案
现在借助附图和实施例详细说明本发明。
在第一方法步骤中，图1a的封装材料4由大气防护层8、无机氧化物层7、载体层6和塑料密封层5构成。
实施例a)至c)描述了每一层可供选择物质的几种方案：
实施例a)：大气防护层8：膜形式的聚氟乙烯(PVF)或聚偏氟乙烯(PVDF)，粘合层(未示出)：聚氨酯无机氧化物层7：氧化硅(SiOx)或氧化铝(Al2O3)用于无机氧化物层7的载体层6：聚乙烯环烷酸酯(PEN)或聚对苯二甲酸乙二酯(PETP)以及膜形式的共挤出物或膜复合物塑料-密封层5：乙烯乙酸乙烯酯(EVA)或离子交联聚合物、聚甲基丙烯酸甲酯(PMMA)、聚氨酯、聚酯或热熔体
实施例b)：大气防护层8：聚氨酯或聚甲基丙烯酸甲酯(PMMA)和稳定的聚对苯二甲酸乙二酯膜(PETP膜)的面涂涂层粘合层(未示出)：聚氨酯无机氧化物层7：氧化硅(SiOx)或氧化铝(Al2O3)用于无机氧化物层7的载体层6：聚乙烯环烷酸酯(PEN)或聚对苯二甲酸乙二酯(PETP)以及膜形共挤出物或膜复合物塑料-密封层5：乙烯乙酸乙烯酯(EVA)或离子交联聚合物、聚甲基丙烯酸甲酯(PMMA)、聚氨酯、聚酯或热熔体
实施例c)：大气防护层8：含氟聚合物如乙烯-四氟乙烯共聚物(ETFE)、聚偏氟乙烯(Polyvinylidenfluorid(PVDF))、聚氟乙烯(Polyvinylidenfluorid(PVF))或其他的含氟聚合物膜无机氧化物层7：氧化硅(SiOx)或氧化铝(Al2O3)塑料-密封层5：乙烯乙酸乙烯酯(EVA)或离子交联聚合物、聚甲基丙烯酸甲酯(PMMA)、聚氨酯、聚酯或热熔体
在实施例a)至c)中，列出了封装材料4的组分，因其协同作用使得薄膜型太阳能电池系统2免受大气的影响和水蒸气的渗透。
大气防护层8最好选择含氟聚合物，它防止薄膜型太阳能电池系统2受到大气的影响，例如受到紫外光的影响。
向例如由PEN或PET-PEN共挤出物组成的载体层6上提供无机氧化物层7，层厚为30-200纳米，是在真空下通过气相沉积的。由载体层6和无机氧化物层7构成的阻挡层9防止水蒸气渗透薄膜型太阳能电池系统2。
带无机氧化物层7的层状结构的优点是水蒸气的渗透性比可比较的涂于PETP膜上的无机氧化物层低10倍，参见图5。这表明：尽管聚对苯二甲酸乙二酯(PETP)用作载体层6时具有令人满意的性能，但是，可通过加入聚对苯二甲酸乙二酯(PEN)显著地降低用克/米2·天(每平方米和每天的克数)表示的水蒸气的渗透性。所述水蒸气的渗透性借助共挤出物PETP-PEN以及纯的PEN并借助每种塑料的两种测量体系由图5证明。
封装材料4中使用的密封层5因其粘合特性而赋予薄膜型太阳能电池系统2额外的防护功能，这是因为薄膜型太阳能电池系统与封装材料4通过密封层粘连在一起的缘故。
在例如采用方案a)至c)构成封装材料4时，有关大气防护层8、阻挡层7、载体层6和密封层5的材料的选择是按本身已知的层叠方法进行的。
与此无关的是，阻挡层7例如氧化硅(SiOx)层是通过气相沉积法沉积在载体层6如聚对苯二甲酸乙二酯(PETP膜)、共挤出的聚对苯二甲酸乙二酯/聚环烷酸酯膜(PETP-PEN膜)上的。
接着在阻挡层7上层压大气防护层8，大气防护层既可以是塑料膜，也可以是塑料膜复合物。密封层5例如聚氨酯粘合剂同样是通过层压形式提供的。
将现在构成的封装材料4放置在图3装置中的备用滚筒13′上。在装料位置13处，薄膜型太阳能电池系统2与刚性载体材料3如玻璃一起放置在传输带(未示出)上，并输送到加热区15。通过控制装置(未示出)，在加热区将薄膜型太阳能电池系统2与刚性载体材料3如玻璃载体一起预热到封装材料4中密封层5的软化温度。现在，不仅将上述的封装材料4，而且将预热到70-180℃的薄膜型太阳能电池系统2与玻璃载体3一起以轧辊对17的形式输送到层压区16处。由于层压区16处的温度较高，优选在70-180℃的范围内，以及轧辊对17施加的压力，优选的压力值为80-400N/cm(输送压)，通过层压形成图1所示的封装光电组件1。组件被送入硬化炉(18)，其中特别是密封层5的硬化是在约120-190℃的温度下进行的。在进行适当的定尺裁剪，在卸出区19取出最终形成的薄膜型组件1。
借助图4的装置详细说明本发明的其他方法。在此情况下，同样按上述方法制备封装材料4，并放置在备用滚筒13′上。将薄膜型太阳能电池系统2与柔性载体11一起放置在另一备用滚筒13′上。
柔性载体11可以是塑料膜或塑料膜复合物。例如含聚酰亚胺的塑料适合用作柔性载体。
接着将封装材料4或薄膜型太阳能电池系统2与柔性载体11一起输送到层压区21。在加热区23、23′加热该两种材料带至密封层5的软化温度，即约70-180℃。按照图4，层压区21例如是一套轧辊对22。此时，至少将一根或两根轧辊加热至封装材料4中密封层5的软化温度，优选至70-180℃。使位于轧辊间隙22′中的预热的封装材料4直接提供到薄膜型太阳能系统2上，由于轧辊的接触压力约为80-400N/cm(输送压)，从而对其施压。接着在加热炉24中对复合体进行加热，加热温度为120-190℃。经过这种层压步骤，完成薄膜型太阳能电池系统2的封装以及图2的光电薄膜组件10的形成。
通过增加备用辊13′的数量，可使用其他的封装材料4′。根据图2可以看出：薄膜型太阳能电池系统2的两侧也是被封装的，从而确保进一步地完善太阳能电池系统2的大气防护层或阻挡层。
概括而言，按照本发明的方法，将封装材料4以及薄膜型太阳能电池系统2与每一载体通过层压彼此复合在一起，在压力和提高的温度下压制，构成复合形式的耐大气性的光电薄膜型组件。本发明方法的特征在于：与已知方法相比，其加工时间短，能耗低。另外，以简单易行的方法提供了一种抗紫外光、水蒸气和其他大气影响的光电薄膜型组件。通过对载体材料，例如塑料膜或塑料膜复合物形式的载体材料的选择，可额外地使光电组件具有柔韧性。
工业实用性
按本发明方法制备的光电薄膜型组件的作用是利用太阳光产生电能。其应用的可行性是多方面的，从用于应急电话或借助结构一体化的屋顶和房屋立面系统构成的野营车的小型发电装置直到大型设备和太阳能电厂。
在室外使用时，发现封装材料耐水蒸气的阻挡作用是通过在载体膜上气相沉积的氧化物层增强的，所述的载体膜由PEN或PETP共挤出物形成。
Claims (12)
1.一种制备光电薄膜型组件(1，10)的方法，该组件包括提供到载体材料(3，11)上的薄膜型太阳能电池系统(2)，必要时其两侧被封装材料复合体(4，4′)包封，该方法的特征在于：在层压步骤中，由防护层(8，9)和密封层(5)形成的用于封装材料复合体(4，4′)的材料带在层压区与另一用于薄膜型太阳能电池系统(2)和其载体材料(3，11)的材料带接触，使得密封层(5)贴着薄膜型太阳能电池系统(2)，并且通过升高的压力和必要时升高的温度形成光电组件(1，10)形式的复合件。
2.根据权利要求1的方法，其特征在于：借助于一对或多对轧辊对进行层压。
3.根据权利要求1或2的方法，其特征在于：再对形成的光电薄膜型组件(1，10)进行硬化。
4.根据权利要求1-3任一项的方法，其特征在于：薄膜型太阳能电池系统(2)的载体材料采用柔性载体材料(11)。
5.根据权利要求4的方法，其特征在于：采用基于塑料膜或塑料膜复合物的柔性载体材料(11)。
6.根据权利要求4的方法，其特征在于：采用基于金属箔或钢带的柔性载体材料(11)。
7.根据权利要求1-3任一项的方法，其特征在于：薄膜型太阳能电池系统(2)的载体材料采用钢性的载体材料(3)。
8.根据权利要求7的方法，其特征在于：采用玻璃作为刚性载体材料(3)。
9.根据权利要求1-8任一项的方法，其特征在于：在封装材料(4，4′)中具有阻挡层(9)，所述阻挡层(9)由大气防护层(8)、无机氧化物层(7)和预定用作无机氧化物层(7)的载体层(6)构成。
10.根据权利要求9的方法，其特征在于：在载体层(6)中，使用基于聚乙烯环烷酸酯(PEN)或聚对苯二甲酸乙二酯(PETP)和聚萘二甲酸乙二醇酯共挤出物的塑料膜或膜复合物。
11.根据权利要求9或10的方法，其特征在于：在阻挡层(9)中使用了厚度为30-200纳米的由氧化铝或氧化硅构成的无机氧化物层(7)。
12.根据权利要求1-11任一项的方法，其特征在于：密封层(5)由热熔融材料，例如聚酰胺或热塑性弹性体和/或离子交联聚合物形成。
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- 2001-03-05 EP EP01911230A patent/EP1297577B1/de not_active Expired - Lifetime
- 2001-03-05 US US10/221,028 patent/US20030029493A1/en not_active Abandoned
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- 2001-03-05 EA EA200200879A patent/EA200200879A1/ru unknown
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- 2001-03-05 BR BR0109057-7A patent/BR0109057A/pt active Pending
- 2001-03-05 PL PL36008401A patent/PL360084A1/pl unknown
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- 2001-03-05 JP JP2001566195A patent/JP2005509265A/ja active Pending
- 2001-03-05 DK DK01911230T patent/DK1297577T3/da active
- 2001-03-05 WO PCT/AT2001/000061 patent/WO2001067523A1/de active IP Right Grant
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- 2001-03-05 CZ CZ20022991A patent/CZ20022991A3/cs unknown
- 2001-03-05 CN CN01806288A patent/CN1418379A/zh active Pending
- 2001-03-05 SI SI200130885T patent/SI1297577T1/sl unknown
- 2001-03-05 CA CA002402395A patent/CA2402395A1/en not_active Abandoned
- 2001-03-05 AT AT01911230T patent/ATE407004T1/de active
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- 2001-03-05 KR KR1020027011765A patent/KR20030028731A/ko not_active Application Discontinuation
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- 2002-09-06 NO NO20024280A patent/NO20024280L/no not_active Application Discontinuation
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Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1968811B (zh) * | 2004-06-17 | 2010-06-16 | 纳幕尔杜邦公司 | 用作光伏电池组件密封层的多层离聚物薄膜 |
| CN100338784C (zh) * | 2004-10-12 | 2007-09-19 | 天津大学 | 多元硫属光电薄膜的连续离子吸附反应制备方法 |
| CN102484160A (zh) * | 2009-08-24 | 2012-05-30 | 纳幕尔杜邦公司 | 用于薄膜光伏电池的阻挡膜 |
| CN102166868A (zh) * | 2009-12-31 | 2011-08-31 | 杜邦太阳能有限公司 | 用于太阳能模块的背层 |
| CN102870232A (zh) * | 2010-06-15 | 2013-01-09 | 赢创工业集团股份有限公司 | 塑料光伏模块及其制造方法 |
| CN103079816A (zh) * | 2010-07-02 | 2013-05-01 | 3M创新有限公司 | 具有包封剂和光伏电池的阻挡组件 |
| CN103025820A (zh) * | 2010-07-30 | 2013-04-03 | 纳幕尔杜邦公司 | 用于光电池的可交联的离聚包封材料 |
| CN103988578A (zh) * | 2011-08-04 | 2014-08-13 | 3M创新有限公司 | 边缘受保护的阻隔组件 |
| CN103988578B (zh) * | 2011-08-04 | 2017-07-21 | 3M创新有限公司 | 边缘受保护的阻隔组件 |
| CN103165707A (zh) * | 2011-12-09 | 2013-06-19 | 纳幕尔杜邦公司 | 用于光伏模块的可交联边缘密封剂 |
| CN104395081A (zh) * | 2012-04-18 | 2015-03-04 | 葛迪恩实业公司 | 用于车顶的被改进的光伏模块和/或其制备方法 |
| CN104395081B (zh) * | 2012-04-18 | 2016-12-07 | 葛迪恩实业公司 | 用于车顶的被改进的光伏模块和/或其制备方法 |
| CN107689401A (zh) * | 2017-09-14 | 2018-02-13 | 旭科新能源股份有限公司 | 一种用于柔性薄膜太阳能电池的卷对卷封装系统及方法 |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2005509265A (ja) | 2005-04-07 |
| PT1297577E (pt) | 2008-10-14 |
| BG107010A (en) | 2003-03-31 |
| EA200200879A1 (ru) | 2003-02-27 |
| WO2001067523A1 (de) | 2001-09-13 |
| CZ20022991A3 (cs) | 2003-02-12 |
| DK1297577T3 (da) | 2009-01-05 |
| EP1297577A1 (de) | 2003-04-02 |
| HUP0300374A2 (en) | 2003-07-28 |
| CY1108574T1 (el) | 2013-03-13 |
| ES2310546T3 (es) | 2009-01-16 |
| AU4031501A (en) | 2001-09-17 |
| EP1297577B1 (de) | 2008-09-03 |
| NO20024280L (no) | 2002-10-06 |
| IL151410A0 (en) | 2003-04-10 |
| PL360084A1 (pl) | 2004-09-06 |
| US20030029493A1 (en) | 2003-02-13 |
| CA2402395A1 (en) | 2001-09-13 |
| EE200200509A (et) | 2004-04-15 |
| MXPA02008674A (es) | 2004-09-06 |
| KR20030028731A (ko) | 2003-04-10 |
| SK12902002A3 (sk) | 2003-05-02 |
| ATE407004T1 (de) | 2008-09-15 |
| BR0109057A (pt) | 2003-06-03 |
| DE50114283D1 (de) | 2008-10-16 |
| NO20024280D0 (no) | 2002-09-06 |
| TR200202116T2 (tr) | 2003-03-21 |
| YU66802A (sh) | 2004-03-12 |
| SI1297577T1 (sl) | 2009-02-28 |
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