CN1968811A - 用作光伏电池组件密封层的多层离聚物薄膜 - Google Patents
用作光伏电池组件密封层的多层离聚物薄膜 Download PDFInfo
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Abstract
本发明为光伏(太阳能)电池,所述电池包括作为密封层的多层层压离聚物薄膜,其中所述层压薄膜的透光率为至少85%和/或雾度小于6%,且其中所述层压薄膜的模量小于15,000psi。
Description
本专利申请要求2004年6月17日提交的美国申请10/870,454的优先权。
发明背景
发明领域
本发明涉及用作光伏(太阳能)电池组件密封材料的薄模。本发明具体涉及用作光伏电池组件密封材料、包含乙烯/酸共聚离聚物的薄膜。
相关技术描述
光伏(太阳能)电池组件是将光能转变为电能的装置,所述装置可用于如动力机器、电气设备和器械。太阳能电池的常规结构由5层结构层组成。常规太阳能电池的各层按照如下顺序构造,从顶层或入射层(即首先接触入射光的层)开始并连续到底板(离入射层最远的层)分别为:(1)入射层/(2)密封层/(3)发电层/(4)第二密封层/(5)底层。
入射层的作用是提供允许阳光进入电池组件的透明保护窗。入射层一般为玻璃板,但相信可为任何对光透明的材料。
密封(密封材料)层用来密封和保护易碎的发电层。一般密封层包括夹住发电层的两聚合物层。两密封层可为相同材料或不同且截然不同的材料。方便起见,除了另有说明,下文中提到密封层时将表示单一密封层或多个密封层。然而,至少第一密封层的光学性质必须使得光能有效地发射到发电层。
常规密封层一般包括乙烯/醋酸乙烯酯共聚物(EVA)。某些密封层采用乙烯单体和烯属不饱和羧酸单体共聚得到的共聚物制得,其中所述共聚物随后完全或部分中和成酸盐。这种中和的乙烯/酸共聚物就是通常所知的离聚物。离聚物可从E.I.DuPont de Nemours andCompany(DuPont)购得。其它材料也可用作密封层。
发电层一般为将阳光的光子转变成电能的硅片。
太阳能电池底层保护太阳能电池组件不受环境的不利影响。太阳能电池底层的要求是:(1)良好的耐气候性(即抵抗气候的影响);(2)高绝缘强度;(3)低透湿气率;和(4)机械强度。底层必须对第二密封层具有良好的附着力以防止电池材料分层。
太阳能电池组件中,不希望密封层模量高,因为如果模量高,光伏电池组件中会产生应力从而导致玻璃顶层层裂、界面破裂或组件粘合失效。已经发现:顶层为玻璃而底层为聚合物材料且密封层为离聚物材料的太阳能电池组件中,离聚物层的模量将太高。商品化材料中的高模量有时可忽略,因为离聚物提供了应用所需的光学性能。遗憾的是,用具有可接受低模量的商品化离聚物取代具有可接受的光学性能但不可接受模量的某些材料是不好的选择,因为其光学性能会不符合需要。
良好的光学性能对于太阳能电池组件相当重要,因为它是使入射到电池的光有效透射到发电层而产生良好性能所必需的。差的透光性减小了光电产生过程的效率和/或产率。
混合具有可接受模量的离聚物和具有可接受光学性能的其它离聚物可使得光学性能和模量为各组件性能的中间值。在需要提高光学性能或模量的情况下这并非是令人满意的结果。
希望在太阳能电池组件生产中提供具有太阳能电池组件所需的物理和光学性能的离聚物密封层。
发明概述
本发明一方面为光学透明多层层压薄膜,所述光学透明多层层压薄膜包括:至少三层离聚物薄膜,其中(a)所述至少三层薄膜中至少两层化学性质彼此不同,(b)所述层压薄膜按照ASTM D882-01测定的模量小于约15,000psi和(c)所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTM D1003-00测定的雾度等于或小于约6%。
本发明另一方面为包含密封层的光伏(太阳能)电池,所述密封层包括光学透明多层层压薄膜,所述薄膜包括:至少三层离聚物薄膜,其中(a)所述至少三层薄膜中的至少两层在化学性质上彼此不同,(b)所述层压薄膜按照ASTM D882-01测定的模量小于约15,000psi和(c)所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTMD1003-00测定的雾度等于或小于约6%。
本发明另一方面为制备光学透明多层层压密封层的方法,所述密封层按照ASTM D882-01测定的模量小于约15,000psi且其中所述层压密封层(i)透过至少约85%的入射可见光和/或(ii)按照ASTMD1003-00测定的雾度等于或小于约6%,所述方法包括将至少三层离聚物薄膜层压在一起的步骤,其中至少有一层薄膜在层压之前独立于其它层薄膜测定时的透光率小于约85%和/或雾度大于约6%。
本发明另一方面为制备用作太阳能电池组件的密封层的光学透明多层层压薄膜的方法,其中所述多层层压薄膜按照ASTM D882-01测定的模量小于约15,000psi且其中所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTM D1003-00测定的雾度等于或小于约6%,所述方法包括共挤出至少三层离聚物薄膜的步骤,其中至少一层共挤出层在层压之前独立于其它层测定时的透光率小于85%和/或雾度大于约6%。
发明详述
本发明的一个实施方案为包括至少三层离聚物薄膜的光学透明多层层压薄膜。术语“光学透明”是指将本发明的至少三层离聚物薄膜组合在一起进行光学测试时,其能透过光谱可见光区至少85%的光。光学透明度可与多层层压薄膜的雾度相关联。在本发明的实施中,所述密封层层压结构的雾度不大于6%。具有雾度大于6%或透光率小于85%的密封层的电池将不能有效产生电能。
就本发明而言,将层压密封材料的最外层称为“光层”,而位于光层之间的至少一层称为“结构层”。构造本发明的多层透明层压薄膜,使得光层与至少一层结构层的反面形成界面。结构层可包括不止一层结构层,条件是它们应为“光学同质的(opticallyhomogenous)”,也就是说所述结构层不会因为与多层结构层结合而造成透明度变差。换句话说,就本发明而言,如果光透过一层结构层与透过多层结构层的透光率基本不变(在实验误差内),就认为多层结构层是光学同质的。
尽管要求本发明的密封层压结构透过至少约85%的入射光和/或雾度小于约6%,但各单独的层压层并非均必须具有满足这些标准的光学性能。具体地讲,不要求本发明所述的至少一层结构层具有满足所述层压结构最低标准的光学性能。实际上,本发明的一个目标是通过制备具有可接受光学性能的层压结构来克服各结构层光学性能较差的缺点。
在本发明的实施中,所述多层密封材料包括至少三层离聚物层,它们层压在一起形成多层层压结构。所述多层层压结构包括:(1)至少两层离聚物光层,其透明度至少为约85%和/或雾度小于约6%,和(2)至少一离聚物结构层,其模量小于约15,000psi且透明度大于约85%和/或雾度大于约6%。
所述光层各自独立透过至少约85%入射到其各自表面的光。优选光层透过至少约88%入射光,且更优选至少约89%入射光。最优选所述光层透过至少约90%入射光。在非常优选的实施方案中,光层可各自独立透过至少约91%、92%、93%、94%、95%入射光。所述光层的雾度优选小于约5%,更优选小于约4%,且最优选小于约3%。所述光层的模量可大于15,000psi而没有负面影响所得层压结构的模量。
在本发明的实施中,所述多层密封材料的光层与所述至少一层结构层在化学上不同。如,至少两层离聚物层之间离聚物的酸组分的百分比可不同,酸组分的中和水平可不同,所述至少两种离聚物中相反离子的种类可不同,同时还可存在或不存在第三种共聚单体。可单独改变或一起改变这些条件的每一个以及其它条件来使得所述光层的化学性质不同于密封层中结构层的化学性质。
在本发明的实施中,所述密封材料的光层可与其它密封层相同或不同。选择所述光层使得:(1)在它们与层压结构其它层的连接界面具有合适附着力;(2)为所述多层层压密封材料提供本文所述的光学性能,从而使得所述密封材料适用于本发明的实施;和(3)所述多层层压密封材料的模量没有提高到高于15,000的水平。优选所述光层的模量小于约15,000。更优选或者作为选择,所述层压结构的光层相同。
所述太阳能电池组件的密封层包括至少一层结构层,所述结构层包括正割模量小于约15,000psi的离聚物。优选所述至少一层结构层的模量小于14,000,且最优选模量小于约13,000。
另一实施方案中,本发明的层压薄膜为多层离聚物层压薄膜,其中所述低模量结构层为包括两层或多层聚合物薄膜的复合薄膜,其中所述复合结构层的模量小于约15,000。优选所述复合结构层的模量小于14,000,且最优选模量小于约13,000。
如果包括所述复合结构层的多层密封材料满足本发明密封材料的光学要求,则所述复合结构层适用于本发明。
除了离聚物外,所述复合结构层可包括赋予所述层压密封材料所需模量和光学性能的任何聚合物。如,所述结构层可为离聚物、聚氨酯、乙烯醋酸乙烯酯(EVA)、聚氯乙烯(PVC)、聚酯、聚缩醛、乙烯酸共聚物(可包括乙烯酸三元共聚物或更多元共聚物)、乙烯丙烯酸酯共聚物(可包括三元共聚物和更多元共聚物),或其它聚合物层:(1)具有合适的物理性能;(2)具有至少85%的透明度或制成具有至少85%的透明度;和(3)可层压成离聚物以制得具有良好附着力的层压结构。就本发明而言,良好附着力是指足以防止太阳能电池组件分层的附着力,可按照常规方法测定。太阳能电池组件中所需的附着力的大小为太阳能电池组件生产领域的普通技术人员所熟知。
在另一实施方案中,本发明的结构层可包括非离聚物聚合物,条件是它具有本文中所述的离子聚合物层的性能,包括对所述光层合适的附着力以防止多层密封材料分层。合适的聚合物包括EVA聚合物,如通常用于太阳能电池组件密封层的那些EVA聚合物。
本发明的多层密封材料令人意外地具有所述光层的光学性能和所述结构层的模量以提供具有用于太阳能电池组件所需的光学性能和所需的模量的密封材料。这种结果是令人意外的,因为所述光层可提供所需光学性能,即使在各结构层的光学性能差的情况下也是如此。
用于实施本发明的离聚物可为乙烯和烯属不饱和C3-C8羧酸共聚得到的共聚物。优选所述不饱和羧酸为丙烯酸或甲基丙烯酸。所述酸共聚物优选包含约8%重量-约20%重量酸,以共聚物总重计。在本发明实施中用作光层的离聚物优选包含约12%重量-约20%重量酸,更优选约14%重量-约19%重量酸,最优选约15%重量-约19%重量酸。少于约12%酸会导致所述光层透光率过低或雾度过高。
在特别优选实施方案中,可用于本发明实施中的结构层优选为共聚物离聚物,更优选包含约8%重量-约12%重量酸的三元共聚物离聚物。应该理解在本发明中所述酸组分包含盐形式的任何中和酸。如果酸为甲基丙烯酸,则所述酸共聚物优选包含约15%重量-约25%重量甲基丙烯酸。共聚物中的酸基可被高度中和,以包括高达约100%的羧酸。优选约10-约90%重量的酸基被中和。这种常规离聚物可从如E.I.DuPont de Nemours and Company(DuPont)购得。
除了所述乙烯和酸组分外,常规离聚物可包括第三种共聚单体组分,其为烯属不饱和羧酸的酯。包括第三种共聚单体的常规离聚物可从如DuPont购得且可适用于本发明实施中,只要是其光学和物理性能适于本发明的用途即可。
本发明的多层层压结构的总厚度为40.0mil以下。优选所述层压结构的总厚度为20.0以下。更优选所述层压结构的总厚度为10mil以下,甚至更优选厚度为4.0mil以下。甚至更优选所述层压结构的总厚度可为约3.0mil以下,或2.0mil以下。密封层所需的厚度可为获得防止易碎发电层受到物理破坏所需的结构性能和获得其它目标如满足电池组件光学和/或电学要求、使用成本有效材料和生产成本最低化之间的平衡。
本发明的光层优选比本发明的结构层更薄,这样所述结构层的模量将决定所述层压结构的模量。所述光层的厚度可各自独立为所述结构层厚度的约50%以下。本发明的层压结构的光层的厚度可各自独立为20mil以下,优选15mil以下,更优选10mil以下,条件是可改变任何薄膜的厚度来平衡所需光学及电学性能,以及生产成本有效太阳能电池组件的实际问题。
在太阳能电池组件生产方法中,将所述组件的各组分,如密封层、发电层和底层叠放在真空层压机中并在真空和加热、加压下层压在一起。
本发明的多层层压薄膜可用于许多用途。本发明的多层薄膜为对玻璃和其它材料如塑料或其它透明材料具有优异附着力的薄膜,因此适合与玻璃或透明塑料一起使用,制备光学透明层压制品,如太阳能电池组件或层压窗或其它安全玻璃。
实施例
实施例和对比实施例仅用于说明,并不对本发明范围进行限定。
对比实施例1
采用Brampton 3层共挤出生产线,利用ZnO为1.19%重量而MI为5.5的乙烯/甲基丙烯酸(15%重量)共聚物树脂(树脂1)制得2mil单层吹塑薄膜。所述薄膜的雾度按照ASTM D1003-00测定。透光率(%T)采用Varian Cary 5uv/vis/nir系统测定。将薄膜从800nm扫描到200nm0并记录500nm处的%T。正割模量按照ASTM D882-01测定。运行对照物以校正各分析方法。结果列于表1中。
对比实施例2
重复对比实施例1的步骤,所不同的是利用ZnO为0.75%重量而MI为4.0的乙烯/甲基丙烯酸(10%重量)共聚物树脂(树脂2)制得2mil单层吹塑薄膜。雾度、正割模量和%T记录在表1中。
实施例1
如下制得2.0mil三层吹塑薄膜:共挤出由树脂1制得的两层0.5mil薄膜层(层1和3)和由树脂2制得的1.0mil薄膜层(层2),制得三层薄膜。雾度、正割模量和%T记录在表1中。
对比实施例3
采用Sano多层挤出生产线挤出树脂1(11.5mil)。雾度、正割模量和%T记录在表1中。
对比实施例4
采用Sano多层挤出生产线挤出树脂2(11.5mil)。雾度、正割模量和%T记录在表1中。
实施例2
采用Sano多层挤出生产线层压挤出结构为[树脂1(0.6mil)/树脂2(10.3mil)/树脂1(0.6mil)]的三层浇铸薄膜(共11.5mil)。雾度、正割模量和%T记录在表1中。
实施例3
采用Sano多层挤出生产线层压挤出结构为[树脂1(1.7mil)/树脂2(8.1mil)/树脂1(1.7mil)]的三层浇铸薄膜(共11.5mil)。雾度、正割模量和%T记录在表1中。
表1
实施例 | 模量(psi)(MD/TD)1 | 雾度% | 透光率(%) |
C1 | 20,694/18,526 | 2.45 | 90.6 |
C2 | 8,138/7,045 | 6.53 | 84.8 |
1 | 10,787/11,789 | 2.37 | 90.4 |
C3 | 22,429/20,525 | 4.63 | 87.8 |
C4 | 9,199/8,259 | 12.50 | 83.7 |
2 | 10,213/10,062 | 3.57 | 88.5 |
3 | 12,479/12,476 | 3.58 | 86.9 |
1MD=纵向,TD=横向
Claims (23)
1.一种光学透明多层层压薄膜,所述层压薄膜包括:至少三层离聚物薄膜,其中(a)所述至少三层薄膜中至少两层化学性质彼此不同,(b)所述层压薄膜按照ASTM D882-01测定的模量小于约15,000psi和(c)所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTM D1003-00测定的雾度等于或小于约6%。
2.权利要求1的层压薄膜,其中所述层压薄膜包括至少两层光层,所述光层各自独立透过至少约85%入射到其各自表面的光和/或雾度小于约6%。
3.权利要求2的层压薄膜,其中所述光层与至少一层结构层的反面接触,且其中所述结构层的模量小于约15,000psi。
4.权利要求3的层压薄膜,其中至少一层光层透过至少约85%的入射光和/或雾度小于约5%。
5.权利要求4的层压薄膜,其中各光层透过至少约85%的入射光和/或雾度小于约5%。
6.权利要求5的层压薄膜,其中至少一层光层的雾度小于约4%。
7.权利要求6的层压薄膜,其中各光层的雾度小于约4%。
8.权利要求7的层压薄膜,其中至少一层光层的雾度小于约3%。
9.权利要求2的层压薄膜,其中所述层压薄膜的总厚度为约40.0mil以下。
10.权利要求9的层压薄膜,其中所述层压薄膜的总厚度为约20.0mil以下。
11.权利要求10的层压薄膜,其中所述层压薄膜的总厚度为约10.0mil以下。
12.权利要求11的层压薄膜,其中所述层压薄膜的总厚度为约4.0mil以下。
13.权利要求11的层压薄膜,其中所述层压薄膜的总厚度为约3.0mil以下。
14.权利要求11的层压薄膜,其中所述层压薄膜的总厚度为约2.0mil以下。
15.权利要求9的层压薄膜,其中所述至少两层光层的厚度各自独立为20.0mil以下。
16.权利要求9的层压薄膜,其中所述至少两层光层的厚度各自独立为15mil以下。
17.权利要求9的层压薄膜,其中所述至少两层光层的厚度各自独立为10mil以下。
18.一种包含至少一层密封层的光伏(太阳能)电池组件,所述密封层包括光学透明多层层压薄膜,所述层压薄膜包括:至少三层离聚物薄膜,其中(a)所述至少三层薄膜中至少两层化学性质彼此不同,(b)所述层压薄膜按照ASTM D882-01测定的模量小于约15,000psi,和(c)所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTM D1003-00测定的雾度等于或小于约6%。
19.权利要求18的太阳能电池组件,其中所述至少一层密封层透过至少约88%的入射光。
20.权利要求19的太阳能电池组件,其中所述至少一层密封层透过至少约89%的入射光。
21.权利要求20的太阳能电池组件,其中所述至少一层密封层透过至少约90%的入射光。
22.一种制备光学透明多层层压密封层的方法,所述多层层压密封层按照ASTM D882-01测定的模量小于约15,000psi,且其中所述层压密封层(i)透过至少约85%的入射可见光和/或(ii)按照ASTMD1003-00测定的雾度等于或小于约6%和(iii)模量小于约15,000,所述方法包括将至少三层离聚物薄膜层压在一起的步骤,其中至少一层薄膜在层压之前的透光率小于约85%和/或雾度大于约6%。
23.一种光学透明多层层压薄膜,所述层压薄膜包括:至少三层离聚物薄膜,其中(a)所述至少三层薄膜中至少两层化学性质彼此不同,(b)所述层压薄膜按照ASTM D882-01测定的模量小于约15,000psi,和(c)所述层压薄膜(i)透过至少约85%的入射可见光和/或(ii)按照ASTM D1003-00测定的雾度等于或小于约6%,其中所述层压薄膜包括至少两层光层和至少一层结构层,所述光层各自独立透过至少约85%入射到其各自表面的光和/或雾度小于约6%,且所述光层的厚度可各自独立为所述结构层的约50%以下。
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2004
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-
2005
- 2005-06-15 CN CN2005800192551A patent/CN1968811B/zh not_active Expired - Fee Related
- 2005-06-15 WO PCT/US2005/021243 patent/WO2006009760A1/en not_active Application Discontinuation
- 2005-06-15 JP JP2007516719A patent/JP4774050B2/ja not_active Expired - Fee Related
- 2005-06-15 EP EP05766589.5A patent/EP1755888B1/en not_active Expired - Fee Related
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102905896A (zh) * | 2010-05-13 | 2013-01-30 | 三井-杜邦聚合化学株式会社 | 多层材料、太阳能电池用密封材料、安全(夹层)玻璃用中间膜、太阳能电池组件及安全(夹层)玻璃 |
CN102905896B (zh) * | 2010-05-13 | 2017-02-08 | 三井-杜邦聚合化学株式会社 | 多层材料、太阳能电池用密封材料、安全(夹层)玻璃用中间膜、太阳能电池组件及安全(夹层)玻璃 |
Also Published As
Publication number | Publication date |
---|---|
EP1755888A1 (en) | 2007-02-28 |
CN1968811B (zh) | 2010-06-16 |
US20050279401A1 (en) | 2005-12-22 |
WO2006009760A1 (en) | 2006-01-26 |
JP4774050B2 (ja) | 2011-09-14 |
EP1755888B1 (en) | 2017-01-11 |
US7902452B2 (en) | 2011-03-08 |
JP2008503366A (ja) | 2008-02-07 |
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