TWI707773B - 用於太陽能電池的背板及其製法 - Google Patents
用於太陽能電池的背板及其製法 Download PDFInfo
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Abstract
本發明公開一種用於太陽能電池的背板及其製法。用於太陽能電池的背板包括一聚烯烴疊層結構和一保護層,保護層設置於聚烯烴疊層結構上。聚烯烴疊層結構包括一反射層以及設置於反射層上的一透光層;其中,透光層包括一連續相和分散於連續相中的一分散相,連續相是由聚烯烴所形成,分散相是由橡膠彈性體所形成,所述分散相在所述透光層中的含量為10重量百分比至25重量百分比。
Description
本發明涉及一種背板及其製法,特別是涉及一種用於太陽能電池的背板及其製法。
一般而言,太陽能電池模組主要是由玻璃蓋板、乙烯-醋酸乙烯共聚物(ethylene-vinyl acetate copolymer,EVA)薄膜、太陽能電池和背板(back panel)所組成。其中,背板是整個太陽能電池模組中與外界接觸面積最大的構件,背板的設置不僅可支撐整個太陽能電池模組,更可阻隔太陽能電池與外界環境,達到保護太陽能電池的效果。
為了接收大量的光能,太陽能電池模組通常會架設於戶外,但如此一來,太陽能電池模組需具備良好的耐候性和耐熱性,以承受戶外的日曬雨淋。並且,太陽能電池模組需具備良好的阻隔性和耐衝擊性,以避免外界環境中的微顆粒、液體或水氣滲入,若外界的微顆粒、液體或水氣不幸侵入太陽能電池模組,則可能會造成太陽能電池的毀損,甚至影響太陽能電池的光電轉換效率。因此,對太陽能電池模組而言,背板的耐候性、耐熱性、阻隔性和耐衝擊性,是影響太陽能電池模組的使用壽命的重要因素。
傳統用於太陽能電池的背板主要包括:可作為穿透層的一透明聚烯烴薄膜、可作為反射層的一聚酯薄膜(例如:聚對苯二甲酸乙二酯薄膜)以及一保護層。然而,由於上述各層間材料的差異,在加工製備背板時,需於聚酯薄膜上的相對兩面上分別進行複合加工,以於聚酯薄膜的相對兩面分別形成穿透層和保護層。也就是說,傳統的背板至少需經過兩次複合加工,才可完成製備。然而,複合加工的成本較高也較容易產生瑕疵,並且,在複合加工的過程中涉及了黏著劑的使用,黏著劑會隨時間老化,而導致黏著力下降。此外,若有水氣滲入背板的結構內,黏著劑的黏著效果也會因此被削弱,而可能導致背板的疊層結構發生剝離現象。
本發明所要解決的技術問題在於,針對現有技術的不足提供一種用於太陽能電池的背板及其製法。
為了解決上述的技術問題,本發明所採用的其中一技術方案是,提供一種用於太陽能電池的背板。用於太陽能電池的背板包括一聚烯烴疊層結構和一保護層,保護層設置於聚烯烴疊層結構上。聚烯烴疊層結構包括一反射層以及設置於反射層上的一透光層;其中,透光層包括一連續相和分散於連續相中的一分散相,所述連續相是由聚烯烴所形成,所述分散相是由橡膠彈性體所形成,所述分散相在所述透光層中的含量為10重量百分比至25重量百分比。
為了解決上述的技術問題,本發明所採用的另外一技術方案是,提供一種用於太陽能電池的背板的製法。用於太陽能電池的背板的製法包括以下步驟:提供一聚烯烴疊層結構,所述聚烯烴疊層結構包括相互堆疊設置的一反射層和一透光層,所述透光層包括一連續相和一分散相,所述連續相是由聚烯烴所形成,所述分散相的是由橡膠彈性體所形成,所述分散相在所述透光層中的含量為10重量百分比至25重量百分比。於聚烯烴疊層結構上塗佈形成一保護層。
本發明的其中一有益效果在於,本發明所提供的用於太陽能電池的背板及其製法,其能通過“透光層包括一連續相和分散於所述連續相中的一分散相,所述分散相是由橡膠彈性體所形成,且所述分散相在所述透光層中的含量為10重量百分比至25重量百分比”的技術手段,以提升背板的耐候性、耐熱性、阻隔性和耐衝擊性。
為使能更進一步瞭解本發明的特徵及技術內容,請參閱以下有關本發明的詳細說明與圖式,然而所提供的圖式僅用於提供參考與說明,並非用來對本發明加以限制。
以下是通過特定的具體實施例來說明本發明所公開有關“用於太陽能電池的背板及其製法”的實施方式,本領域技術人員可由本說明書所公開的內容瞭解本發明的優點與效果。本發明可通過其他不同的具體實施例加以施行或應用,本說明書中的各項細節也可基於不同觀點與應用,在不悖離本發明的構思下進行各種修改與變更。另外,本發明的附圖僅為簡單示意說明,並非依實際尺寸的描繪,事先聲明。以下的實施方式將進一步詳細說明本發明的相關技術內容,但所公開的內容並非用以限制本發明的保護範圍。
應當可以理解的是,本文中所使用的術語“或”,應視實際情況可能包括相關聯的列出項目中的任一個或者多個的組合。
為了提供可應用於太陽能電池模組,且具備良好耐候性、耐熱性、阻隔性和耐衝擊性的背板,本發明提供了一種用於太陽能電池的背板及其製法。本發明用於太陽能電池的背板的製法可排除黏著劑的使用,進而解決以往使用黏著劑所會衍生的問題;並且,省略了複合加工的步驟後,便可降低背板的生產成本。
首先,請參閱圖1所示,圖1為太陽能電池模組的立體分解示意圖。太陽能電池模組主要是由一玻璃蓋板G、一乙烯-醋酸乙烯共聚物(EVA)層F、一太陽能電池S、另一乙烯-醋酸乙烯共聚物層F以及一背板B所組成。
市面上的太陽能電池種類繁多,本發明的背板B可適用於各種太陽能電池S,例如:矽晶型太陽能電池或薄膜型太陽能電池,但是本發明不以上述所舉例的為限。太陽能電池S相對兩側的兩個乙烯-醋酸乙烯共聚物層F是作為封裝材料,可完整包覆於太陽能電池S外,並達到保護太陽能電池S的效果。另外,玻璃蓋板G設置於太陽能電池S主要接收光線的一側,玻璃蓋板G的作用為防止環境中的物質與太陽能電池S接觸,而影響太陽能電池S的光轉換效率。而背板B設置在太陽能電池S相對於玻璃蓋板G的另一側,關於本發明提供的背板B的結構,將於後進一步詳述。
請合併參閱圖2和圖3所示,圖2為本發明的用於太陽能電池的背板的側視示意圖,圖3為本發明的用於太陽能電池的背板的製法的步驟流程圖。於本實施例中,背板B包括一聚烯烴疊層結構1和一保護層2。保護層2設置於聚烯烴疊層結構1上,以達到保護聚烯烴疊層結構1的效果。
在製備用於太陽能電池的背板的製造方法中,首先,提供一聚烯烴疊層結構1(步驟S100)。聚烯烴疊層結構1具有良好的光反射效果,可使散射的光線反射至太陽能電池S,以提升太陽能電池模組中太陽能電池S的光利用率和光轉換效率;並且,聚烯烴疊層結構1具有良好的耐候性、耐熱性、阻隔性和耐衝擊性,可避免外在環境因素(如溫度或溼度)影響太陽能電池S的效能,並可防止太陽能電池S與外界物質接觸造成磨損,以達到保護太陽能電池S的效果。保護層2具有良好的抗侵蝕效果,可保護太陽能電池S以及聚烯烴疊層結構1不受外界環境的侵蝕。
值得注意的是,本發明的聚烯烴疊層結構1是以共擠出(co-extrusion)方式形成,過程中不需塗佈黏膠或設置黏著層。另一方面,本發明的保護層2是以塗佈(coating)方式形成於聚烯烴疊層結構1上,過程中同樣不需添加黏著劑。由此可知,本發明的背板B免除了黏著劑的使用,也省略了複合加工的步驟,具有生產成本較低的優點,並可克服以往會因水氣滲入,導致黏著劑的黏性降低的問題。
具體來說,本發明的聚烯烴疊層結構1包括一反射層11和一透光層12,透光層12設置於反射層11上。反射層11和透光層12可通過共擠出的方式於相同的製程步驟中製備而得,也就是說,反射層11和透光層12可以是一體成型。由於本發明的反射層11和透光層12是一體成型,故反射層11和透光層12之間具有較佳的密著性,如此一來,本發明的聚烯烴疊層結構1較不會有水氣滲入,而導致反射層11或透光層12剝落的問題。並且,相較於聚酯材料而言,聚烯烴的材料本身就具有較佳的耐水性。
於本實施例中,反射層11的材料和透光層12的材料都是聚烯烴,因此,在共擠出過程時,不需另外於形成反射層11的材料或是形成透光層12的材料中添加架橋劑,通過熱壓的方式即可結合。然而,上述製備聚烯烴疊層結構1的方式僅為說明,本發明並非以上述為限。
聚烯烴疊層結構1中的反射層11,可反射未被太陽能電池S所接收的散射光線回太陽能電池S,以提升太陽能電池S的光利用率和光轉換效率。於本實施例中,以反射層11的總重為基準,形成反射層11的材料中包括30重量百分比至60重量百分比的聚丙烯以及40重量百分比至70重量百分比的聚乙烯。
具體來說,本發明的聚丙烯可以是均聚聚丙烯(polypropylene homopolymer,簡稱PP-H)、嵌段共聚聚丙烯(polypropylene block copolymer,簡稱PP-B)或無規共聚聚丙烯(polypropylene random copolymer,簡稱PP-B)中的至少一種。於一較佳實施例中,形成反射層11的材料中的聚丙烯為均聚聚丙烯。
具體來說,聚乙烯可以是乙烯均聚物、乙烯共聚物或其混合物。乙烯均聚物是指僅使用乙烯作為單體所聚合而成的聚合物,乙烯共聚物是指由乙烯和另一種或多種單體共同聚合而成的共聚物。另外,聚乙烯可另區分為高密度聚乙烯(high density polyethylene,簡稱HDPE)、低密度聚乙烯(low density polyethylene,簡稱LDPE)、線性低密度聚乙烯(linear low density polyethylene,簡稱LLDPE)或茂金屬聚乙烯(metallocene polyethylene,簡稱mPE),但不以此為限。於一較佳實施例中,形成反射層11的材料中的聚乙烯是選用線性聚乙烯。
並且,為了提升反射層11的光反射效果,反射層11中可另包括10重量百分比至35重量百分比的反射填料。反射填料可以為二氧化鈦、蒙托土(Montmorillonite,MMT)、二氧化矽、鋁銀漿(Aluminiumpaste)、雲母粉(Mica powder)、硫酸鋇或碳酸鈣,但不以此為限。於一較佳實施例中,選用二氧化鈦作為反射填料,二氧化鈦不僅可提高太陽能電池模組的光轉換效率,還可提升反射層11的耐候性,進而提升太陽能電池模組的使用壽命。
聚烯烴疊層結構1中的透光層12,具有良好的耐候性、耐熱性、阻隔性和耐衝擊性,可達到保護太陽能電池S的效果,並可延長太陽能電池模組的使用壽命。於本實施例中,以透光層12的總重為基準,形成透光層12的材料中包括60重量百分比至80重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。其中,聚丙烯中摻混了20重量百分比至30重量百分比的橡膠彈性體,換句話說,若以透光層12的總重為基準,橡膠彈性體的含量為12重量百分比至24重量百分比,然而,本發明不以上述為限。較佳的,在透光層12中橡膠彈性體的含量為10重量百分比至25重量百分比。更佳的,在透光層12中橡膠彈性體的含量為20重量百分比至25重量百分比。通過橡膠彈性體的添加,可提升透光層12的剛性,以達到與以往聚酯薄膜相近的物理特性。
具體來說,橡膠彈性體可以是以乙烯或丙烯作為基礎,並在乙烯(或丙烯)的聚合過程中添加丙烯(或乙烯)、丁烯或辛烯等單體,以合成出聚烯烴彈性體(Polyolefin elastomer,POE);或者,橡膠彈性體可以是將聚乙烯、聚丙烯和其他烯烴系材料(例如但不限於:二元乙丙橡膠或三元乙丙橡膠)共混,所形成的熱塑性烯烴彈性體(Thermoplastic olefin elastomer,TPO)。
於一較佳實施例中,形成透光層12的材料中的聚丙烯為嵌段共聚聚丙烯,形成透光層12的材料中的聚乙烯是選用線性聚乙烯,且透光層12中的橡膠彈性體為乙烯-丙烯橡膠。在乙烯-丙烯橡膠中,乙烯和丙烯的含量可在合成時進行調整。較佳的,乙烯-丙烯橡膠中的乙烯含量為25重量百分比至55重量百分比。更佳的,乙烯-丙烯橡膠中的乙烯含量為30重量百分比至50重量百分比。當乙烯的含量低於25重量百分比或是高於55重量百分比時,透光層12無法具有良好的抗衝擊性。
另請參閱圖4所示,就微觀結構而言,本發明的透光層12中包括一連續相121和一分散相122,分散相122均勻的分散於連續相121中。
在本發明中,形成連續相121的材料為聚烯烴,即連續相121是由前述聚乙烯和聚丙烯所形成。通過調控聚乙烯和聚丙烯的含量比,可使透光層12具有可媲美以往聚酯薄膜的硬度和機械強度。具體來說,若以透光層12的總重為基準,形成連續相121的材料中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯。另一方面,形成分散相122的材料為橡膠彈性體,即分散相122是由乙烯-丙烯橡膠所形成。通過橡膠彈性體的添加,可提升透光層12的耐衝擊性。
本發明通過調控分散相122在透光層12中的含量,可使透光層12具有良好的成膜性和耐衝擊性。若分散相122在透光層12中的比例過高,則會降低透光層12的成膜性以及黏著性,進而影響背板B的特性;若分散相122在透光層12中的比例過低,則透光層12無法具備足夠的耐熱性和耐衝擊性。
請再合併參閱圖2和圖3所示,在製備用於太陽能電池的背板的製造方法中,於聚烯烴疊層結構1上形成一保護層2(步驟S102)。保護層2設置於聚烯烴疊層結構1上,保護層2可選擇與反射層11接觸或是與透光層12接觸。於本實施例中,保護層2設置於聚烯烴疊層結構1上,並與透光層12接觸。如此一來,當背板B應用於太陽能電池模組時,未被太陽能電池S所接收的光線可通過較短的光程被反射層11反射,以降低光線能量的損失,進而提升太陽能電池模組的光轉換效率。然而,本發明不以此為限。
為了提升保護層2抵抗外界環境侵蝕的效果,保護層2的材料中包括一含氟聚合物,含氟聚合物包括聚偏二氟乙烯(polyvinylidene difluoride,簡稱PVDF)、聚四氟乙烯(polytetrafluoroethylene,簡稱PTFE)、乙烯-四氟乙烯共聚物(polyethylene tetrafluoroethylene,簡稱ETFE)、聚三氟氯乙烯(polychlorotrifluoroethene,簡稱PCTFE)以及乙烯-聚三氟氯乙烯共聚物(polyethylene chlorotrifluoroethene,簡稱ECTFE)之中的一種或兩種以上的組合。於一較佳實施例中,含氟聚合物為乙烯-四氟乙烯共聚物,且保護層2的厚度為15微米至25微米。
[實施例的有益效果]
本發明的其中一有益效果在於,本發明所提供的用於太陽能電池的背板及其製法,其能通過“透光層12包括一連續相121和分散於所述連續相121中的一分散相122”、“所述連續相121是由聚烯烴所形成,所述分散相122是由橡膠彈性體所形成”以及“所述分散相在所述透光層12中的含量為10重量百分比至25重量百分比”的技術特徵,以提升背板B的耐候性、耐熱性、阻隔性和耐衝擊性。
更進一步來說,本發明所提供的用於太陽能電池的背板及其製法,其能通過“所述反射層11和所述透光層12是以共擠出方式一體成型”以及“所述保護層2是以塗佈方式形成於所述聚烯烴疊層結構1上”的技術特徵,排除黏著劑的使用,以降低生產成本以及產品的不良率,並可避免長時間使用後黏著劑老化,或因水氣滲入降低黏著劑黏性所衍生的問題。
更進一步來說,本發明所提供的用於太陽能電池的背板及其製法,其能通過“所述連續相的材料中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯”或“乙烯-丙烯橡膠中的乙烯含量為25重量百分比至55重量百分比”的技術特徵,以使透光層12可具有與傳統聚酯薄膜相近的硬度特性,並可具有一定的阻隔性和耐衝擊性。
更進一步來說,本發明所提供的用於太陽能電池的背板及其製法,其能通過“所述反射層包括10重量百分比至35重量百分比的反射填料”的技術特徵,可提升反射層11的反射效果,以將散射的光線反射至太陽能電池S,進而提升太陽能電池模組的光轉換效率。
更進一步來說,本發明所提供的用於太陽能電池的背板及其製法,其能通過“所述保護層2與所述透光層12接觸”的技術特徵,以縮短未被太陽能電池S接收的光線被反射層11所反射的光程,並降低光線的能量損失,進而提升太陽能電池模組的光轉換效率。
以上所公開的內容僅為本發明的優選可行實施例,並非因此侷限本發明的申請專利範圍,所以凡是運用本發明說明書及圖式內容所做的等效技術變化,均包含於本發明的申請專利範圍內。
G:玻璃蓋板
F:乙烯-醋酸乙烯共聚物層
S:太陽能電池
B:背板
1:聚烯烴疊層結構
11:反射層
12:透光層
121:連續相
122:分散相
2:保護層
圖1為太陽能電池模組的立體分解示意圖。
圖2為本發明的用於太陽能電池的背板的側視示意圖。
圖3為本發明的用於太陽能電池的背板的製法的步驟流程圖。
圖4為本發明的透光層的微觀結構的側視示意圖。
B:背板
1:聚烯烴疊層結構
11:反射層
12:透光層
2:保護層
Claims (11)
- 一種用於太陽能電池的背板,其包括:一聚烯烴疊層結構,其包括一反射層以及設置於所述反射層上的一透光層;其中,所述透光層包括一連續相和分散於所述連續相中的一分散相,所述連續相是由聚烯烴所形成,形成所述連續相的聚烯烴中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯;所述分散相是由橡膠彈性體所形成,所述分散相在所述透光層中的含量為12重量百分比至24重量百分比;以及一保護層,其設置於所述聚烯烴疊層結構上,所述保護層不包含聚酯薄膜。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,所述橡膠彈性體為乙烯-丙烯橡膠,且所述乙烯-丙烯橡膠中的乙烯含量為25重量百分比至55重量百分比。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,形成所述反射層的材料為聚烯烴,所述反射層和所述透光層是以共擠出方式一體成型。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,以所述反射層的總重為基準,形成所述反射層的材料中包括30重量百分比至60重量百分比的聚丙烯以及40重量百分比至70重量百分比的聚乙烯。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,以所述反射層的總重為基準,所述反射層包括10重量百分比至35重量百分比的反射填料。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,所述保護層的厚度為15微米至25微米。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,形 成所述保護層的材料包括含氟聚合物,所述含氟聚合物包括聚偏二氟乙烯、聚四氟乙烯、乙烯-四氟乙烯共聚物、聚三氟氯乙烯以及乙烯-聚三氟氯乙烯共聚物中的一種或兩種以上的組合。
- 如申請專利範圍第1項所述的用於太陽能電池的背板,其中,所述保護層與所述透光層接觸。
- 一種用於太陽能電池的背板的製法,其包括:提供一聚烯烴疊層結構;其中,所述聚烯烴疊層結構包括相互堆疊設置的一反射層和一透光層,所述透光層包括一連續相和一分散相,所述連續相是由聚烯烴所形成,形成所述連續相的聚烯烴中包括48重量百分比至56重量百分比的聚丙烯和20重量百分比至40重量百分比的聚乙烯;所述分散相是由橡膠彈性體所形成,所述分散相在所述透光層中的含量為12重量百分比至24重量百分比;以及於所述聚烯烴疊層結構上形成一保護層,所述保護層不包含聚酯薄膜。
- 如申請專利範圍第9項所述的用於太陽能電池的背板的製法,其中,所述反射層和所述透光層是以共擠出方式一體成型。
- 如申請專利範圍第9項所述的用於太陽能電池的背板的製法,其中,所述保護層是以塗佈方式形成於所述聚烯烴疊層結構上。
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CN202010086627.9A CN112659678A (zh) | 2019-10-15 | 2020-02-11 | 用于太阳能电池的背板及其制法 |
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