TWI556956B - 具有聚醯胺與聚丙烯層之多層膜於製造光伏打模組上之用途 - Google Patents

具有聚醯胺與聚丙烯層之多層膜於製造光伏打模組上之用途 Download PDF

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TWI556956B
TWI556956B TW101137467A TW101137467A TWI556956B TW I556956 B TWI556956 B TW I556956B TW 101137467 A TW101137467 A TW 101137467A TW 101137467 A TW101137467 A TW 101137467A TW I556956 B TWI556956 B TW I556956B
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安卓亞斯 帕里克
馬汀 威爾普茲
哈羅德 哈格
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贏創工業股份有限公司
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Description

具有聚醯胺與聚丙烯層之多層膜於製造光伏打模組上之用途
本發明關於具有聚醯胺與聚丙烯層之多層膜於製造太陽能模組上之用途。
也常被稱為光伏打模組的太陽能模組適用於自日光發電且由包含太陽能電池系統作為核心層之層合板所組成。此核心層係由封裝材料包封，該封裝材料充當為免於機械和風化(weathering)相關影響的防護之。
活性太陽能電池在此係介於前蓋件與背蓋件之間。前蓋件為透明且通常由玻璃所組成；其係利用常由乙烯-乙酸乙烯酯共聚物所組成的黏著性促進劑層結合至包含太陽能電池之層。背蓋件保證電遮蔽且充當為免於風化影響(諸如UV光)的防護及水氣阻障層。
由氟聚合物膜與聚酯所組成的膜複合物目前用作為背蓋件的標準物。在外側之氟聚合物膜保證抗風化性、聚酯膜機械穩定性及所欲電絕緣性質。在內部之另外的氟聚合物膜適用於黏附至太陽能電池系統的密封層。然而，此等氟聚合物膜對用作為太陽能電池本身的包埋材料之密封層僅具有低黏著性。另外，氟聚合物膜僅貢獻低微程度的電絕緣性，其導致必須使用比較厚的聚酯膜。
WO 2008138022因此提出以耐綸-12(PA12)膜替換在此等複合物中的兩個氟聚合物膜。在其發展中， WO 2011066595提出面對太陽能電池之熱塑性層包含光反射填料，諸如二氧化鈦，而遠離太陽能電池之熱塑性層包含第二填料，諸如玻璃纖維、矽灰石或雲母，其造成此層較高的導熱性。例證之熱塑物係出自於聚醯胺、聚酯或聚醯胺與聚烯烴之摻合物的群組。明確述及的是PA11、PA12和PA1010，及其與聚烯烴之摻合物。
在此種類之組裝中的聚醯胺層與聚丙烯層之組合由於非常好的電絕緣性質而具有優點。然而，此熱塑性組合達不到足夠的層黏著性。
本發明的目的係提供具有好的中間層黏著性之多層膜，作為太陽能模組用之背膜的多層膜確保有效的電絕緣性。
此目的係藉由使用多層膜作為光伏打模組之背蓋件而達成，該多層膜包含下列層：a)模製組成物太陽能電池面對層，該模製組成物包含在各例子中以整體模製組成物為基準計至少35重量%，較佳為至少40重量%，更佳為至少45重量%，尤其佳為至少50重量%，而最佳為至少55重量%之聚醯胺含量，c)模製組成物中間層，該模製組成物包含在各例子中以整體模製組成物為基準計至少35重量%，較佳為至少40重量%，更佳為至少45重量%，尤 其佳為至少50重量%，而最佳為至少55重量%之聚丙烯比例，及e)模製組成物外層，該模製組成物包含在各例子中以整體模製組成物為基準計至少35重量%，較佳為至少40重量%，更佳為至少45重量%，尤其佳為至少50重量%，而最佳為至少55重量%之聚醯胺含量，且在根據a)與c)的該等層之間及在根據c)與e)的該等層之間的黏著性係藉由選自下列的措施而產生：
1.在根據c)的層中，存在有具有足夠酸酐基團濃度以促進黏著性之聚丙烯。在此例子中，可將此模製組成物的全部聚丙烯或僅其一部分官能化。關於官能化聚丙烯，同樣應用於下一段落中。就此例子的另一選擇，聚丙烯模製組成物亦可包含官能化聚烯烴(諸如乙烯、丙烯酸甲酯及/或丙烯酸乙酯及亦與甲基丙烯酸環氧丙酯或順丁烯二酸酐(MAn)之共聚物)，其與聚丙烯可相容且提供足以黏附於聚醯胺層之官能基，更特別為酸酐基團或環氧化物基團。當官能化聚烯烴與聚丙烯以分子互溶或在丙烯中化合之後以熱力學穩定方式分散時，則此官能化聚烯烴與聚丙烯可相容，使得其給予根據a)和e)的層足夠牢固的相黏著性。
2.在根據a)與c)的該等層之間引入黏著性促進劑層b)及在根據c)與e)的該等層之間引入黏著性促 進劑層d)。黏著性促進劑的本性不重要。有可能使用足以使層互相牢固地連結的任何黏著性促進劑，所以該等層在製造期間及亦在後續使用期間不會分層。在最簡單的例子中，黏著性促進劑為含有酸酐基團之聚丙烯，該酸酐基團係藉由聚丙烯與不飽和二羧酸酐、不飽和二羧酸或不飽和二羧酸單烷基酯之熱或自由基反應的已知方式而以有效黏附於相鄰層之聚醯胺的足夠濃度引入。適合的試劑之實例包括順丁烯二酸、順丁烯二酸酐、順丁烯二酸單丁酯、反丁烯二酸、烏頭酸或衣康酸酐。在此方式中，較佳地將0.1至4重量%之不飽和酐接枝在聚丙烯上。依照先前技藝，例如亦可將不飽和二羧酸酐或其前驅體與另外的不飽和單體(諸如苯乙烯、a-甲基苯乙烯或茚)一起接枝在聚丙烯上。另一選擇地，黏著性促進劑可為聚醯胺與攜帶酸酐基團的此聚丙烯種類之摻合物。此外，黏著性促進劑亦可包含非官能化聚丙烯。亦適合的是聚丙烯與適合的添加劑(諸如乙烯、甲基丙烯酸甲酯及/或丙烯酸乙酯及亦與甲基丙烯酸環氧丙酯或MAn之共聚物)之摻合物。另外適合的黏著性促進劑係由聚醯胺、官能化乙烯-丙烯橡膠及非官能化聚丙烯所組成。亦適合的是EP-A-1 216 823中所揭示之黏著性促進劑。若黏著性促進劑包含聚醯胺，則應選擇與根據a)和e)的層中相同的聚醯胺，或應選擇足以與其黏 附者可相容之聚醯胺。
聚醯胺可為部分結晶性聚醯胺，例如PA6、PA66、PA610、PA612、PA10、PA810、PA106、PA1010、PA11、PA1011、PA1012、PA1210、PA1212、PA814、PA1014、PA618、PA512、PA613、PA813、PA914、PA1015、PA11、PA12或稱為聚酞醯胺(PPA)之半芳族聚醯胺(聚醯胺之命名係對應於國際標準，前面的數字(等)表示起始二胺的碳原子數目及最後的數字(等)表示二羧酸的碳原子數目。若只提到1個數字，此意指起始材料為α,ω-胺基羧酸或自其衍生之內醯胺；其餘者參考H.Domininghaus,Die Kunststoffe und ihre Eigenschaften[The polymers and their properties],pages 272 ff.,VDI-Verlag,1976)。適合的PPA為例如PA66/6T、PA6/6T、PA6T/MPMDT(MPMD代表2-甲基五亞甲基二胺)、PA9T、PA10T、PA11T、PA12T、PA14T和該等類型與脂族二胺及脂族二羧酸或與ω-胺基羧酸或內醯胺之共聚縮合物。部分結晶性聚醯胺具有超過25焦耳/公克之熔合焓，其係在第二加熱步驟中根據ISO 11357之DSC方法及熔融峰積分所測量。
聚醯胺亦可為半結晶性聚醯胺。半結晶性聚醯胺具有4至25焦耳/公克之熔合焓，其係在第二加熱步驟中根據ISO 11357之DSC方法及熔融峰積分所測量。適合的半結晶性聚醯胺之實例為：- 1,10-癸二酸或1,12-十二烷二酸及4,4'-二胺基二環 己基甲烷(PA PACM10和PA PACM12)之聚醯胺，來自具有35至65%之反，反異構物含量的4,4'-二胺基二環己基甲烷；- 以前述部分結晶性聚醯胺為底質的共聚物；以及- 前述部分結晶性聚醯胺與可相容之非晶形聚醯胺的摻合物。
聚醯胺亦可為非晶形聚醯胺。非晶形聚醯胺具有低於4焦耳/公克之熔合焓，其係在第二加熱步驟中根據ISO 11357之DSC方法及熔融峰積分所測量。非晶形聚醯胺之實例為：- 對苯二甲酸及/或間苯二甲酸及2,2,4-與2,4,4-三甲基六亞甲基二胺的異構物混合物之聚醯胺，- 間苯二甲酸及1,6-六亞甲基二胺之聚醯胺，- 對苯二甲酸/間苯二甲酸與1,6-六亞甲基二胺之混合物的共聚醯胺，隨意地在與4,4'-二胺基二環己基甲烷之混合物中，- 對苯二甲酸及/或間苯二甲酸、3,3'-二甲基-4,4'-二胺基二環己基甲烷及月桂內醯胺或己內醯胺之共聚醯胺，- 1,12-十二烷二酸或癸二酸、3,3'-二甲基-4,4'-二胺基二環己基甲烷及隨意的月桂內醯胺或己內醯胺之(共)聚醯胺，- 間苯二甲酸、4,4'-二胺基二環己基甲烷及月桂內醯胺或己內醯胺之共聚醯胺， - 1,12-十二烷二酸及4,4'-二胺基二環己基甲烷(在低的反，反異構物含量之例子中)之聚醯胺，- 對苯二甲酸及/或間苯二甲酸及經烷基取代之雙(4-胺基環己基)甲烷同系物之(共)聚醯胺，隨意地在與六亞甲基二胺之混合物中，- 隨意地與另外的二胺一起的雙(4-胺基-3-甲基-5-乙基環己基)甲烷及隨意地與另外的二羧酸一起的間苯二甲酸之共聚醯胺，- 間-伸二甲苯二胺與另外的二胺(例如，六亞甲基二胺)之混合物及隨意地與另外的二羧酸(例如，對苯二甲酸及/或2,6-萘二羧酸)一起的間苯二甲酸之共聚醯胺，- 雙(4-胺基環己基)甲烷與雙(4-胺基-3-甲基環己基)甲烷之混合物及具有8至14個碳原子的脂族二羧酸之共聚醯胺，以及- 包含1,14-十四烷二酸與芳族、芳基脂族或環脂族二胺的混合物之聚醯胺或共聚醯胺。
該等實例可藉由添加另外的組分(例如，己內醯胺、月桂內醯胺或二胺/二羧酸組合)或藉由以其他組分部分或完全替換起始組分而達到非常重大程度的改變。
聚醯胺亦可為聚醚酯醯胺或聚醚醯胺。聚醚酯醯胺係例如從DE-A-25 23 991和DE-A-27 12 987已知；該等含有聚醚二醇作為共單體。聚醚醯胺係例如從DE-A-30 06 961已知；該等含有聚醚二胺作為共單體。
在聚醚二醇或聚醚二胺中，聚醚單元可以例如1,2-乙二醇、1,2-丙二醇、1,3-丙二醇、1,4-丁二醇或1,3-丁二醇為底質。聚醚單元亦可具有混合型結構，例如具有源自二醇之單元的無規或嵌段式分布。聚醚二醇或聚醚二胺之重量平均莫耳質量為200至5000公克/莫耳，而較佳為400至3000公克/莫耳；其在聚醚酯醯胺或聚醚醯胺中的比例較佳為4至60重量%，而更佳為10至50重量%。適合的聚醚二胺係藉由對應之聚醚二醇以還原胺化作用或與丙烯腈偶合及接著氫化而獲得；其在市場上可自例如Huntsman Corp.以JEFFAMINE® D或ED類型或ELASTAMINE®類型之形式或自BASF SE以聚醚胺D系列之形式取得。若使用支鏈聚醚醯胺，則亦有可能另外使用較少量的聚醚三胺，例如JEFFAMINE® T產品。優先選擇使用在鏈中以每個醚氧原子計含有平均至少2.3個碳原子的聚醚二胺或聚醚三胺。根據本發明，由於更好的抗水解性而以聚醚醯胺較佳。
聚丙烯原則上可為任何市場上習知的聚丙烯類型，實例為同排或對排均聚丙烯、丙烯與乙烯及/或1-丁烯之無規共聚物、丙烯-乙烯嵌段共聚物及類似者。聚丙烯可以任何已知的方法製備，例如藉由Ziegler-Natta方法或利用二茂金屬催化作用。例如，可能存在有衝擊改質組分，諸如EPM橡膠或EPDM橡膠或SEBS。聚丙烯較佳為丙烯-乙烯嵌段共聚物，亦常稱為多相共聚物。此種類之多相共聚物可藉由例如兩相程序而製備，其運作過程大致如下： 首先使用例如Ziegler-Natta觸媒製備高同排聚丙烯，在特定的環境中可能存在有少量乙烯，製得無規共聚物。此材料係作為多相共聚物之基質起作用。在第二反應步驟中(隨意地在不同的反應器中)，隨意地引入第二觸媒，例如二茂金屬觸媒。接著進行乙烯與丙烯的共聚合反應，此聚合反應發生在第一聚合物的凹穴中。結果於此併入第二聚合物。在一個較佳的具體例中，以共聚合形式之嵌段共聚物或多相共聚物含有至少0.5重量%，至少0.6重量%，至少0.7重量%，至少0.8重量%或至少0.9重量%，及亦不超過20重量%，不超過15重量%，不超過12重量%，不超過10重量%或不超過8重量%之乙烯。此外，至多15重量%之1-丁烯可併入共聚合形式中。
根據a)的層之模製組成物可包含前述聚醯胺中之一或其複數種的混合物。另外，可以模製組成物之整體聚合物含量為基準計存在有至多40重量%之其他熱塑物，例如衝擊改質橡膠或聚烯烴，諸如聚乙烯或聚丙烯。依照先前技藝，任何存在的橡膠或聚烯烴較佳地包含官能基，以其獲得與聚醯胺基質的相容性。另外，可存在有習用於聚醯胺之助劑和添加劑，尤其為光及/或熱穩定劑，或較佳亦為光反射填料，例如二氧化鈦(WO 2011066595)。
根據c)的層之模製組成物可包含習用於聚丙烯之助劑和添加劑，尤其為光及/或熱穩定劑、光反射填料(例如，二氧化鈦)和強化填料(例如，玻璃纖維、矽灰石或雲母)。
關於根據e)的層之模製組成物，可應用與根據a)的層之模製組成物相同者，而關於填料，亦可應用與根據c)的層之模製組成物相同者。另外，根據e)的層之模製組成物可著色及/或具有消光劑。
各個膜層通常具有下列厚度：‧根據a)和e)的層：15至100微米，而較佳為25至50微米；‧根據c)的層：100至500微米，而較佳為150至400微米；‧根據b)和d)的層：3至40微米，而較佳為5至25微米。
依照本發明所使用之多層膜可以所有的先前技藝方法製造，例如共擠壓或層合。將多層膜結合至太陽能電池埋入其中的密封層，例如藉由層合或黏接。由於在根據a)的層中之聚醯胺含量，在層合的例子中獲得與密封層好的黏著性。所使用之密封層可為根據先前技藝常使用之任何材料。
本發明亦提供使用根據申請專利範圍的多層膜所製造之光伏打模組。
本發明係以下文之實例方式例證。下列的模製組成物係出於此目的而製造；〝份〞通常為重量份：
用於外層之混練物1：
將79.25份VESTAMID® L1901 nf(PA12)、0.5份IRGANOX® 1098(位阻酚抗氧化劑)、0.2份TINUVIN® 312(UV吸收劑)與20份二氧化鈦Sachtleben R 420在220℃之機筒溫度藉助雙軸擠壓機(Coperion Werner & Pfleiderer ZSK 25 WLE,36 L/D)而混合。將擠壓物藉助水浴而冷卻且切碎；接著將丸粒在強加空氣之烘箱中以80℃經12小時乾燥。
用於中間層之混練物2：
將79.6份Hostalen® EPD60R(丙烯-乙烯嵌段共聚物)、20份TEC 110高嶺土與0.4份IRGANOX® 1010(位阻酚抗氧化劑)在200℃之機筒溫度藉助雙軸擠壓機(Coperion Werner & Pfleiderer ZSK 25 WLE,36 L/D)而混合。將擠壓物藉助水浴而冷卻且切碎；接著將丸粒在強加空氣之烘箱中以80℃經12小時乾燥。
用於中間層之混練物3：
將75.6份Hostalen® EPD60R、4份LOTADER® AX 8900(乙烯、丙烯酸甲酯與甲基丙烯酸環氧丙酯之三聚物)、20份TEC 110高嶺土與0.4份IRGANOX® 1010在200℃之機筒溫度藉助雙軸擠壓機(Coperion Werner & Pfleiderer ZSK 25 WLE,36 L/D)而混合。將擠壓物藉助水浴而冷卻且切碎；接著將丸粒在強加空氣之烘箱中以80 ℃經12小時乾燥。
用於中間層之混練物4：
將43.6份VESTAMID® L1901、32份Hostalen® EPD60R、4份LOTADER® AX 8900、20份TEC 110高嶺土與0.4份IRGANOX® 1010在200℃之機筒溫度藉助雙軸擠壓機(Coperion Werner & Pfleiderer ZSK 25 WLE,36 L/D)而混合。將擠壓物藉助水浴而冷卻且切碎；接著將丸粒在強加空氣之烘箱中以80℃經12小時乾燥。
用於黏著性促進劑層之混練物5：
將95.6份Hostalen® EPD60R、4份LOTADER® AX 8900與0.4份IRGANOX® 1010在200℃之機筒溫度下藉助雙軸擠壓機(Coperion Werner & Pfleiderer ZSK 25 WLE,36 L/D)而混合。將擠壓物藉助水浴而冷卻且切碎；接著將丸粒在強加空氣之烘箱中以80℃經12小時乾燥。
多層膜之擠壓：
使用來自Collin之多層膜系統(300毫米狹縫模具，0-6毫米間隙寬度，用於3-層膜或5-層膜之共擠壓進料塊)製造3-和5-層膜(中間層和黏著性促進劑層之加工溫度為約210℃，及外層之加工溫度為約230℃)。層厚度分配係設定如下：
a/c/e：50微米/250微米/50微米
a/b/c/d/e：50微米/10微米/230微米/10微米/50微米將結果顯示於表1中。

Claims (3)

  1. 一種多層膜作為光伏打模組的背蓋件之用途，該多層膜包含下列層：a)模製組成物太陽能電池面對層，該模製組成物包含以整體模製組成物為基準計至少35重量%之聚醯胺含量，c)模製組成物中間層，該模製組成物包含以整體模製組成物為基準計至少35重量%之聚丙烯比例，及e)模製組成物外層，該模製組成物包含以整體模製組成物為基準計至少35重量%之聚醯胺含量，其中在根據a)與c)的該等層之間及在根據c)與e)的該等層之間的黏著性係藉由選自下列的措施而產生：1.在根據c)的該層之模製組成物中，存在有具有足夠酸酐基團濃度以促進黏著性之聚丙烯，或存在有提供足以黏附於聚醯胺層之官能基的聚丙烯可相容之官能化聚烯烴，以及2.在根據a)與c)的該等層之間引入黏著性促進劑層b)及在根據c)與e)的該等層之間引入黏著性促進劑層d)。
  2. 根據申請專利範圍第1項之用途，其中‧根據a)和e)的該等層具有15至100微米之厚度， ‧根據c)的該層具有100至500微米之厚度，及‧根據b)和d)的該等層具有3至40微米之厚度。
  3. 一種光伏打模組，其係使用根據前述申請專利範圍中任一項之多層膜而獲得。
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