TWI485874B - 以輥層壓製程製造太陽光電模組之方法 - Google Patents

以輥層壓製程製造太陽光電模組之方法 Download PDF

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Publication number
TWI485874B
TWI485874B TW097103620A TW97103620A TWI485874B TW I485874 B TWI485874 B TW I485874B TW 097103620 A TW097103620 A TW 097103620A TW 97103620 A TW97103620 A TW 97103620A TW I485874 B TWI485874 B TW I485874B
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Taiwan
Prior art keywords
solar photovoltaic
photovoltaic module
manufacturing
module according
film
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TW097103620A
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English (en)
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TW200849632A (en
Inventor
Andreas Karpinski
Bernhard Koll
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Kuraray Europe Gmbh
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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Description

以輥層壓製程製造太陽光電模組之方法
本發明係關於藉由利用一聚乙烯基丁醛(PVB)基膜之輥層壓製程製造薄膜太陽光電模組。
薄膜太陽光電模組通常係由光敏半導體膜(於下文中稱為太陽能電池單元)所組成，其中該膜係如藉由蒸鍍、氣相沈積、濺鍍或濕分離施用於主要透明板上並經提供以在必要時以類似透明外蓋給予提供以防外部影響。該等太陽能電池單元經常被層壓在一塊玻璃與如藉由視情況透明之黏著劑的幫助由玻璃所製成之蓋板之間。該黏著劑必須完全密封該等太陽能電池元件、係UV安定的並在該層壓製程後完全無氣泡。
例如，如DE 41 22 721 C1或DE 41 28 766 A1中所揭示般，硬化澆鑄樹脂或可交聯乙烯乙酸乙烯酯(EVA)基系統經常用作透明黏著劑。這些黏著劑系統可經調整以未硬化狀態具有可無氣泡地覆蓋該太陽能電池單元之低黏度。一旦加入硬化劑或交聯劑，獲得一具機械抗性之黏著劑層。此類太陽光電模組之缺點係其高製造成本；特別係在大尺寸表面元件的情況下，將太陽能電池單元嵌入液態澆鑄樹脂及其受控硬化係一不易監測之製程。而且，部分澆鑄樹脂在 數年後具有起泡或分層之傾向。
硬化黏著劑系統之替代方法係使用聚乙烯基丁醛(PVB)基膜。在此情況下，太陽能電池單元係經一或多層PVB膜覆蓋且這些在高壓及高溫下與所需覆蓋材料組合以製造一層壓板。藉由PVB膜的幫助製造太陽光電模組之方法係(例如)由DE 40 26 165 C2、DE 42 278 60 A1、DE 29 237 70 C2、De 35 38 986 C2、DE 197 32 217、DE 40 26 165 、US6,160,215、WO 02/103809、US6,660,556、US 2005/0115667或US4,321,418所揭示。在這些論文中係將PVB膜用於嵌入晶質太陽能電池單元中；但未曾描述薄膜太陽光電模組之單層系統或適合用於這些模組之製造方法。
將PVB膜用於太陽光電模組中作為層壓玻璃係揭示(例如)於DE 20 302 045 U1、EP 1617487 A1及DE 35 389 86 C2。這些專利說明書同樣係關於將太陽能電池封裝於兩PVB膜之間。
在薄膜太陽光電模組之情況下，將太陽能電池直接施用在載體，如一塊玻璃或可撓曲聚合物或金屬載體上。視載體之組態而定，封裝太陽能電池係不可能的。而且，薄膜太陽光電模組可以任何尺寸且大量製成。製造具有太陽能電池嵌在PVB膜間之太陽光電模組之已知方法無法十分自動化地以工業規模製造具有薄膜太陽光電模組之層壓板。
再者，DE 35 38 986 C2及DE 42 27 860揭示藉由一層壓製程在較高溫度及壓力下製造太陽光電模組。將一對輥用於此目的中係未曾描述過。
本發明目的因此係提供一種利用熱塑性中間膜製造薄膜太陽光電模組之方法，其有助於連續及/或可自動化製造。
令人驚訝地發現一種利用一對輥之層壓製程亦適合用於層壓機械上不適合的太陽能電池。
本發明目的因此係一種製造一太陽光電模組之方法，其係藉於50至150℃之溫度下，特別係於60至150℃下在至少一對輥之間擠壓一層體而以至少一基於含塑化劑之聚乙烯縮醛之中間膜層壓該層體，其中該層體係由施用至少一太陽能電池單元之第一載體及第二載體所組成。
較佳係將0.5牛頓/毫米(N/mm)至100牛頓/毫米，特別係10牛頓/毫米至50牛頓/毫米之線壓力施用於壓榨機處。線壓力係指該對輥相對於該膜寬度之表面壓力。
為了防止蓋板受到毀壞，該層體之前緣及/或後緣處(層壓板開始及終止處)的線壓力可降低至上擠壓輥之靜重或藉由 移開上擠壓輥而降低至零。
而且，若該層體中有缺陷存在，如電接點或導體路徑，可能必須降低該層體通過該輥壓榨機之傳送速率，因此線壓力有較長時間可發揮作用。依此方式可達到較佳空氣去除及缺陷對聚乙烯縮醛之黏性。
圖1顯示具有兩對輥之適合設備的概要設計圖。
根據本發明方法係利用一或多個，較佳係各由一對擠壓輥所組成之兩個壓榨機進行。在此情況下，該層體係在至少一對輥之間以相同或不同線壓力並在相同或不同溫度下擠壓。
此種設備已知係用於製造層壓玻璃且通常具有至少一個加熱隧道以提高溫度或確保在具有兩個壓榨機之設備中第一壓榨機前後之溫度固定。亦可想到加工應在具有至少一個加熱隧道以提高或確保最後一個壓榨機下游之溫度固定的設備或裝有超過兩個壓榨機並各具有加熱隧道上游之設備中進行。
上述溫度至少與最後一對必須通過之輥前的層體有關。視情況可在最後一對輥之前插入額外對有或無加熱區上游之輥，其中在此情況下，該層體可呈現上述溫度或亦低於50℃ 或60℃之溫度。
根據本發明，該等層體係在擠壓前於加熱隧道中如利用IR、微波照射或對流分別加熱至50℃或60℃至150℃之溫度，較佳係分別為70℃和80℃至100℃。該等層壓板之溫度可如利用無接觸輥射高溫計測量。
基於含塑化劑之聚乙烯縮醛之膜較佳係包含非交聯聚乙烯基丁醛(PVB)，其係藉由丁醛縮醛化聚乙烯基醇所獲得。
同樣可使用交聯聚乙烯縮醛，特別係交聯聚乙烯基丁醛(PVB)。適合的交聯聚乙烯縮醛係(例如)描述於EP 1527107 B1及WO 2004/063231 A1(含羧基之聚乙烯縮醛之熱自交聯)、EP 1606325 A1(經聚醛交聯之聚乙烯縮醛)及WO 03/020776 A1(經乙醛酸交聯之聚乙烯縮醛)。完全引用這些專利申請案之揭示內容。
亦可以其他或額外醛，如彼等具有5-10個碳原子之醛，例如戊醛進行縮醛化。
為製造聚乙烯縮醛所需之聚乙烯基醇亦可為本發明架構內由水解乙烯基乙酸酯/乙烯共聚物所製成之三聚物。這些化合物通常係超過98%水解度並包含1至10重量%乙烯基單位(如獲自Kururay Europe GmbH之"Exceval"型)。該縮醛 化可如用於聚乙烯基醇般進行。
基於上述聚乙烯縮醛，特別係PVB之適合膜另外包含50-85重量%或50-80重量%之聚乙烯縮醛、50-20重量%或50-15重量%之塑化劑及小量黏性調節劑、抗結塊劑及UV安定劑。此類膜於下係縮寫成PVB膜。用於層壓安全玻璃之PVB膜之主要製造及組成物係描述於(例如)EP 185 863 B1、EP 1 118 258 B1或WO 02/102591 A1中。
在一本發明之特殊具體實施例中，太陽光電模組具有聲阻尼特性，其中該等膜中至少一者具有隔音特性。PVB基隔音膜係描述於如EP 1 118 258 B1或EP 387 148 B1中，本文將完全引用該揭示內容。根據DIN EN ISO 717所量得，根據EP 1 118 258 B1之隔音膜增加層壓安全玻璃在範圍從1,000至3,500Hz之符合頻率中的聲限尼至少2dB。
基於含塑化劑聚乙烯縮醛之膜的厚度較佳係約為這些膜之標準工業厚度，如0.38、0.51、0.76、1.14、1.52或2.28毫米。
基於含塑化劑聚乙烯縮醛之膜具有較佳係以Rz>35微米且Rz<180微米，較佳係Rz>50微米且Rz<150微米，特佳係Rz>70微米且Rz<130微米，特別係Rz>90微米且Rz<130微米之粗糙度施用於一側或特佳係施用於兩側之表面結 構。若表面粗糙度Rz低於35微米，在為使該物質流至該導體路徑或其他配件附近所需之溫度下，該層壓板邊緣在已完全擠出空氣之前過早密合。此結果係在層壓板中間產生氣穴(氣泡)。若有過度表面粗糙度(Rz>180微米)存在，為熔蝕粗糙度波峰所需能量增加並使該製程變成無法接受的長。
根據EP 0 185 863 B1，該膜之表面結構可藉由塑膠熔化物自擠壓噴嘴出現之前立刻擠壓通過所謂流動或熔態破裂製程而製得。不同粗糙程度可藉由改變出口模間隙及就在噴嘴出口處之噴嘴口溫度。此方法產生一不規則，幾乎係等向粗糙度。在此情況下，粗糙度測量實際上由所有方向所量得係相等的，雖然個別高處及凹地的高度及分布係不規則的。
或者，該膜表面結構可如根據EP 06112163或EP 06112159藉由壓花施用。在此情況下，在該表面上產生一均勻粗糙度/粗糙結構。
表面粗糙度Rz 或粗糙值Rz 係根據DIN EN ISO 4287 所量得。該等測量值指示係別用Mahr型S2粗機度測量單元、具有機械單階段按鈕MFW-250之進料裝置PGK所取得。
然後在各情況下可使擠壓體暴露在較大或較低壓力及較高 溫度下。此可根據已知蒸壓、真空環或真空袋製程，如根據EP 1 235 683 B1進行。
在真空袋製程之情況下，將擠壓層體置於塑膠或橡膠袋中。然後此經氣密封並具有真空閥，較佳係位於該塊中間。涉及大尺寸體處，亦可提供兩個真空閥。利用真空泵，先產生一200毫巴以下之真空度並在室溫下進行抽真空至少5分鐘。然後，在循環空氣箱中將夾層加熱至140℃並保持真空。在此期間加熱速率為4至6℃/分鐘，視熱輸出量而定，因此在20至30分鐘後達到140℃之保持溫度。然後將溫度保持在140℃達30分鐘。然後在去除真空之前，必需將溫度降低至最低60℃。事實上，令擠壓體暴露在介於0.01與300毫巴之較低壓力及介於100與200℃間之溫度下。
或者，可使用蒸壓製程。彼等熟諳此技者將熟悉這些製造層壓玻璃之製程。其係在近7至15巴之較高壓力及130至145℃之溫度下進行10至120分鐘。
根據本發明可使用之膜必須確實且無氣泡地覆蓋或密封太陽能電池單元及其電連接；同時太陽光電模組需要最小可能之整體厚度。為了達到此目的。該等膜係適合在製造條件下"產生"太陽能電池單元及其電連接，即在層壓條件下呈現特定流動能力。
聚乙烯縮醛基膜黏接玻璃之能力可經由黏性調節劑如揭示於WO 03/033583之有機酸之鹼金屬及/或鹼土金屬鹽的添加而設定。已證實乙酸鉀及/或乙酸鎂係特別適合的。為了獲得高黏性值，可能必須使用膜而不添加黏性調節劑如鹼金屬及/或鹼土金屬鹽鹽。
根據本發明太陽光電模組之第一及/或第二載體可由玻璃、塑膠或金屬或這些材料之層壓板所組成，其中該等載體中至少一者必須係透明的。一或兩載體同樣可能呈層壓玻璃(即由至少兩塊玻璃與至少一膜所製成之層壓板)或其間具有氣體空間之絕緣玻璃形式。自然地，亦可組合這些材料。
亦可將太陽能電池單元施用於第一載體，特別係可撓曲載體並在由含塑化劑之聚乙烯縮醛所製成之兩層與兩(較佳係透明的)載體之間擠壓之。圖3至5各顯示根據本發明所製成之層壓板的概要設計。其中T1、T2及T3代表載體材料，F代表一含塑化劑之聚乙烯縮醛膜或層，S代表太陽能電池且E代表個別太陽能電池間可能需要之任何電接點。在圖3及4中，將太陽能電池或光活性層施用於載體材料中，藉以在圖4所示變化例中較佳係使用可撓曲載體T3。
太陽光電模組中所用之太陽能電池不必具有任何特殊特性。可使用晶質或非晶質、無機或有機半導體系統施用於 第一載體中。為了供應一適當電壓，數個太陽能電地可為電互連。太陽能電池，在薄膜模型的情況下亦稱為功能層之厚度係至少0.1微米。太陽能電池之電連接所需之導體路徑的厚度通常為>50微米。
圖2顯示一太陽光電模組之概要設計，其中S代表太陽能電池且P代表導體路徑。
根據本發明所製成之太陽光電模組亦可用作表面元件、屋面、溫室屋頂、隔音牆、陽台或欄杆元件或作為窗戶組件。
 實例
在根據圖1之設備中各情況下90℃之溫度(最後一個壓榨機之後)及35牛頓/毫米之線壓力下以3米/分鐘之線速度擠壓一薄膜模組，其量得為L30公分xB20公分且具有一3.2毫米之玻璃厚度及兩條各離邊緣20毫米且寬為2毫米及厚為近250微米之縱向導體路徑。該層壓板之進行方向係經選擇以致導體路徑離開模組之點係在背面且最後擠壓。粗糙度Rz為近100微米之Trosifol HR 100型膜(Kuraray Europe GmbH)係用作含塑化劑之聚乙烯縮醛膜。
該等壓榨機之線壓力係由該膜體之前100毫米及最後30毫米降低至上輥之靜重。
獲得具有低混濁之無氣泡層壓板。
可在後續蒸壓製程中140℃及12巴下以30分鐘之保持時間完全除去混濁。取代蒸壓製程，混濁亦可在真空製程中145℃及150毫巴下以2小時之保持時間去除。
根據本發明方法因此係適合用於製造太陽光電模組；視情況可藉由下游製程階段除去混濁。
P1‧‧‧導體路徑
P2‧‧‧導體路徑
S‧‧‧太陽能電池
T1‧‧‧載體材料
T3‧‧‧載體材料
F‧‧‧含塑化劑之聚乙烯縮醛膜或層
E‧‧‧電接點
T2‧‧‧載體材料
圖1顯示具有兩對輥之適合設備的概要設計圖。
圖2顯示一太陽光電模組之概要設計。
圖3顯示根據本發明所製成層壓板之概要設計
圖4顯示根據本發明所製成層壓板之概要設計
圖5顯示根據本發明所製成層壓板之概要設計

Claims (9)

  1. 一種製造一太陽光電模組之方法，其係藉於50至150℃之溫度下在至少一對輥之間擠壓一層體以至少一基於含塑化劑之聚乙烯縮醛之中間膜層壓該層體，其中該層體係由施用至少一太陽能電池單元之第一載體及第二載體所組成，其中該基於含塑化劑之聚乙烯縮醛之膜一側或兩側上的粗糙值Rz係介於35微米與180微米之間。
  2. 根據申請專利範圍第1項之製造一太陽光電模組之方法，其特徵在於該等輥對間之擠壓係在0.5牛頓/毫米至100牛頓/毫米之線壓力下進行。
  3. 根據申請專利範圍第1或2項中任一項之製造一太陽光電模組之方法，其特徵在於該層體係在至少兩對輥之間相同或不同線壓力及相同或不同溫度下擠壓。
  4. 根據申請專利範圍第1項之製造一太陽光電模組之方法，其特徵在於該基於含塑化劑之聚乙烯縮醛之膜具有一規則粗糙結構。
  5. 根據申請專利範圍第1項之製造一太陽光電模組之方法，其特徵在於該基於含塑化劑之聚乙烯縮醛之膜具有一不規則粗糙結構。
  6. 根據申請專利範圍第1項之製造一太陽光電模組之方法，其特徵在於 該第一及/或第二載體係由玻璃、塑膠、金屬或這些材料之層壓板、層壓玻璃及/或絕緣玻璃所組成，前提係該等載體中至少一者係透明的。
  7. 根據申請專利範圍第1項之製造一太陽光電模組之方法，其特徵在於 令該擠壓體處於一較高或較低壓力及一較高溫度下。
  8. 根據申請專利範圍第8項之製造一太陽光電模組之方法，其特徵在於 令該擠壓體暴露於一0.01至300毫巴之較低壓力及一100至200℃之溫度下。
  9. 根據申請專利範圍第8項之製造一太陽光電模組之方法，其特徵在於 令該擠壓體暴露於一7至15巴之較高壓力及一130至145℃之溫度下。
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