WO2018102189A1 - An electrode isolating structure and a solar cell assembly - Google Patents

An electrode isolating structure and a solar cell assembly Download PDF

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Publication number
WO2018102189A1
WO2018102189A1 PCT/US2017/062710 US2017062710W WO2018102189A1 WO 2018102189 A1 WO2018102189 A1 WO 2018102189A1 US 2017062710 W US2017062710 W US 2017062710W WO 2018102189 A1 WO2018102189 A1 WO 2018102189A1
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WO
WIPO (PCT)
Prior art keywords
eva
isolating structure
electrode isolating
vinyl acetate
particles
Prior art date
Application number
PCT/US2017/062710
Other languages
French (fr)
Inventor
Shuangming MAO
Rui PAN
Original Assignee
3M Innovative Properties Company
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Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Publication of WO2018102189A1 publication Critical patent/WO2018102189A1/en

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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
    • H01L31/04—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 adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/04—Homopolymers or copolymers of ethene
    • C09J123/08—Copolymers of ethene
    • C09J123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
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    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • H—ELECTRICITY
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Definitions

  • the present invention relates to the field of solar cell assemblies, in particular, to an electrode isolating structure that can be used in a solar cell assembly, and a solar cell assembly comprising the electrode isolating structure.
  • a solar cell assembly typically comprises a glass 2, two EVA layers 3, solar cells 4 encapsulated between the two EVA layers 3, and a back plate 5.
  • an electrode isolating structure 8 is typically provided between the positive electrode 6 and the negative electrode 7.
  • a UV-transmittant encapsulating EVA material may be selected as the EVA layers 3.
  • this design would result in yellowing of the electrode isolating structure 8 encapsulated in the EVA layers 3 due to UV irradiation, which may affect the stability and appearance of the solar cell assembly.
  • tin slag stuffing often occurs at the joints of the positive and negative busbars and the solder strip, which results in oversized solder points between the solder strip and the busbars; and the electrode isolating structure 8 would most likely be subjected to delamination in the process of hydrothermal aging.
  • the electrode isolating structure not only is weather resistant (anti-UV, hydrothermal aging resistant), but it also improves the adhesion between the electrode isolating structure and the solar cells and the adhesion between the electrode isolating structure and the busbars.
  • an electrode isolating structure comprises: a crosslinked anti-UV EVA layer comprising a coupling agent, a UV absorbent, a UV stabilizer, ethylene vinyl acetate (EVA) particles, and a peroxide crosslinking agent in an amount of less than 2% by weight; a first adhesive layer selected from one or a combination of the following: an EVA particles-containing coating, an acrylic coating, a fluroresin coating, a polyurethane coating, an epoxy resin coating; a polyester resin layer; and a second adhesive layer comprising ethylene vinyl acetate (EVA) particles.
  • a crosslinked anti-UV EVA layer comprising a coupling agent, a UV absorbent, a UV stabilizer, ethylene vinyl acetate (EVA) particles, and a peroxide crosslinking agent in an amount of less than 2% by weight
  • a first adhesive layer selected from one or a combination of the following: an EVA particles-containing coating, an acrylic coating, a fluroresin coating, a polyurethan
  • the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer comprise vinyl acetate in an amount of from 5% to 45%. According to some embodiments, the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer have a melt flow index (MFI) greater than 10.
  • MFI melt flow index
  • the crosslinked anti-UV EVA layer is comprised of the peroxide crosslinking agent in an amount of from 0.5 wt.% to 1.5 wt.%, the coupling agent in an amount of from 0.5 wt.% to 1.5 wt.%, the UV absorbent in an amount of from 0 to 5 wt.%, the UV stabilizer in an amount of from 0 to 5 wt.%, and the ethylene vinyl acetate (EVA) particles in an amount of from 90 wt.% to 99 wt.%.
  • EVA ethylene vinyl acetate
  • the coupling agent is selected from silane coupling agents or titanate coupling agents.
  • the crosslinked anti-UV EVA layer has a thickness of 50 - 500 ⁇ .
  • the first adhesive layer is an ethylene vinyl acetate (EVA) particles- containing coating, wherein the ethylene vinyl acetate (EVA) particles comprise vinyl acetate in an amount offrom 5% to 45%.
  • EVA ethylene vinyl acetate
  • the first adhesive layer is comprised of the ethylene vinyl acetate (EVA) particles in an amount of from 95 wt.% to 99 wt.%, a UV stabilizer in an amount of from 0 to 5 wt.%, and a coupling agent in an amount of from 0 to 5 wt.%.
  • EVA ethylene vinyl acetate
  • the ethylene vinyl acetate (EVA) particles in the first adhesive layer have a melt flow index in the range of 10 - 50.
  • the ethylene vinyl acetate (EVA) particles in the second adhesive layer have a melt flow index in the range of 2 - 10.
  • the polyester resin layer comprises one or more of: polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polybutylene terephthalate (PBT), polymethylmethacrylate (PMMA).
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • PC polycarbonate
  • PBT polybutylene terephthalate
  • PMMA polymethylmethacrylate
  • the anti-UV performance and hydrothermal aging resistant performance of the electrode isolating structure provided in the present invention are improved; the adhesion of the electrode isolating structure with both the solar cells and the busbars is also improved.
  • the present invention solves the technical problem of the electrode isolating structure becoming yellow over time due to UV irradiation, which in turn may affect the stability and appearance of the solar cell assembly; further, the present invention also solves the problem of appearance defects of the electrode isolating structure such as delamination that may occur at the solder points.
  • a solar cell assembly comprising the electrode isolating structure of this invention is also provided.
  • Fig. 1 is a schematic diagram of the structure of a solar cell assembly
  • Fig. 2 is a schematic diagram of the electrode isolating structure in accordance with some embodiments of the present invention.
  • Melt Flow Index a flow rate of a melt measured under a load of 2.16 Kg at 190°C according to the test method provided in ASTM D 1238.
  • the electrode isolating structure 8 comprises, in order from top to bottom: a crosslinked anti-UV EVA layer 81, a first adhesive layer 82, a polyester resin layer 83, and a second adhesive layer 84.
  • the crosslinked anti-UV EVA layer 81 comprises a peroxide crosslinking agent, a coupling agent, a UV absorbent, a UV stabilizer, and ethylene vinyl acetate (EVA) particles, wherein the peroxide crosslinking agent is in an amount of less than 2% by weight;
  • the first adhesive layer may be selected as an ethylene vinyl acetate (EVA) particles-containing coating;
  • the second adhesive layer comprises ethylene vinyl acetate (EVA) particles.
  • the crosslinked anti-UV EVA layer 81 has anti-UV properties, adhesive properties and hydrothermal aging resistant properties, and may be comprised of the peroxide crosslinking agent in an amount of from 0.5 wt.% to 1.5 wt.%, the coupling agent in an amount of from 0.5 wt.% to 1.5 wt.%, the UV absorbent in an amount of from 0 to 5 wt.%, the UV stabilizer in an amount of from 0 to 5 wt.%, and the ethylene vinyl acetate (EVA) particles in an amount of from 90 wt.% to 99 wt.%.
  • the thickness of the crosslinked anti-UV EVA layer 81 is in the range of from 50 ⁇ to 500 ⁇ , and preferably, is 140 ⁇ .
  • the inventors have found from the research that addition of the peroxide crosslinking agent can improve the crosslinking properties of the electrode isolating structure.
  • a too high amount of the peroxide crosslinking agent is quitely likely to lead to a remnant, resulting in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure upon lamination and hydrothermal aging of the solar cell assembly.
  • the components in the crosslinked anti-UV EVA layer should show synergistic effects, and the crosslinked anti-UV EVA layer should interact with other layers of the electrode isolating structure.
  • the peroxide crosslinking agent is in an amount of from 0.5 wt.% to 1.5 wt.%; the coupling agent is in an amount of from 0.5 wt.% to 1.5 wt.%; the UV absorbent is in an amount of from 0.1 wt.% to 2 wt.%; the UV stabilizer is in an amount of from 0.1 wt.% to 2 wt.%; and the ethylene vinyl acetate (EVA) particles are in an amount of from 93 wt.% to 97 wt.%.
  • EVA ethylene vinyl acetate
  • the coupling agent may be a silane coupling agent (for example, KH550, KH560, KH570), a titanate coupling agent, or the like.
  • the UV absorbent may be selected from salicylates, benzophenones, benzotriazoles, substituted acrylonitriles, or triazines.
  • benzophenone UV absorbents may include UV-9 (2-hydroxy-4- methoxybenzophenone), UV-531 (2-hydroxy-4-n-octoxy-benzophenone), UV-24 (2,2'-dihydroxy-4- methoxybenzophenone), and the like;
  • the benzotriazole UV absorbents may include UV-326 ((2'- hydroxy-3 '-tertbutyl-5 '-methylphenyl)-5-chloro-benzotriazole), UV-P (2-(2'-Hydroxy-5 '- methylphenyl)benzotriazole, and the like;
  • the triazine UV absorbents may include triazine- 5(2,4,6-tri(2'-hydroxy-4'-n-octoxyphenyl)-l,3,5-triazine, and the like.
  • the UV stabilizer may include hindered amines and the like.
  • Typical UV stabilizers may include, such as TINUVIN 622, TINUVIN 770, TINUVIN 783, TINUVIN P and TINUVIN 788 from BASF; CYASORB UV 1 164, CYASORB UV 2126, CYASORB UV 3346, CYASORB UV 3853, and CYASORB THT series of products from Cytec.
  • the crosslinking agent may be organic peroxide initiators, such as benzoyl peroxide (BPO), tert-amyl perbenzoate (TAPA), tert-butyl peroxy-3,3,5-trimethylhexanoate (TBPMH), tert-butyl peroxybenzoate (TBPB), tert-butyl peroxy-2-ethylhexyl carbonate (TBEC), dicumyl peroxide (DCP), tert-butyl cumyl peroxide (TBCP), and the like.
  • BPO benzoyl peroxide
  • TAPA tert-amyl perbenzoate
  • TPMH tert-butyl peroxy-3,3,5-trimethylhexanoate
  • TBPB tert-butyl peroxybenzoate
  • TBEC tert-butyl peroxy-2-ethylhexyl carbonate
  • DCP dicumyl peroxide
  • TBCP
  • the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is greater than 10, wherein the vinyl acetate (VA) is in an amount of from 5% to 45%, which facilitates the crosslinking.
  • MFI melt flow index
  • PV1300, PV1400Z from DuPont and PV280 from Samsung Total may be used.
  • the first adhesive layer 82 has anti-UV and adhesive properties, and may be comprised of the ethylene vinyl acetate (EVA) particles in an amount of from 95 wt.% to 99 wt.%; a UV stabilizer in an amount of from 0 to 5 wt.%; and a coupling agent in an amount of from 0 to 5 wt.%.
  • the thickness of the first adhesive layer 82 is in the range of from 5 ⁇ to 100 ⁇ , and preferably, is 30 ⁇ .
  • the coupling agent used may be a silane coupling agent or a titanate coupling agent.
  • the UV stabilizer may be selected as TINUVIN 622, TINUVIN 770 from BASF, and
  • the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is greater than 10; and more preferably, the MFI is in the range of from 10 to 50, wherein the vinyl acetate (VA) is in an amount of from 5% to 45%.
  • MFI melt flow index
  • VA vinyl acetate
  • TAISOX 7660M EVA from Formosa Plastics may be selected.
  • an acrylic coating, a fluroresin coating, a polyurethane coating, an epoxy resin coating, or various coupling agent coatings may be used in the first adhesive layer; and the thickness of the first adhesive layer may be in the range of from 1 ⁇ to 20 ⁇ .
  • the thickness of the polyester resin layer 83 may be in the range of from 50 ⁇ to 250 ⁇ .
  • the polyester resin layer may be a white polyethylene terephthalate (PET); and more preferably, it may be a hydrolysis resistant PET having good weather resistant properties.
  • PET white polyethylene terephthalate
  • the thickness of the layer is preferably 100 ⁇ .
  • polycarbonate (PC), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), and polymethylmethacrylate (PMMA) may also be used as the polyester resin layer.
  • the second adhesive layer 84 has adhesive and fixing properties, and the thickness thereof is in the range of from 5 ⁇ to 100 ⁇ , with 30 ⁇ being preferable.
  • the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is less than 10, with 2-10 of MFI being more preferable; the vinyl acetate (VA) is in an amount of from 5% to 45%.
  • MFI melt flow index
  • VA vinyl acetate
  • 51 10J EVA from Yangtze BASF may be used.
  • the electrode isolating structure of the present invention may be disposed between the positive electrode 6 and the negative electrode 7 of adjacent solar cells in the solar cell assembly to isolate the positive and the negative electrodes.
  • the crosslinked anti-UV EVA layer and the first adhesive layer of the electrode isolating structure of the present invention can keep out ultraviolet light effectively; and the crosslinked anti- UV EVA layer can provide much better adhesion and hydrothermal aging resistant performance.
  • the electrode isolating structure of the present invention is used in a solar cell assembly, the solar cell assembly is much safer in use with long service life.
  • the structure provides strong isolation between the positive electrode and the negative electrode, so as to protect the solar cell assembly. Examples
  • the EVA particles 3, the peroxide crosslinking agent, the coupling agent, the UV absorbent, and the UV stabilizer are mixed well in a certain ratio at atmospheric temperature (10 - 30°C), and then heated to obtain the crosslinked anti-UV EVA film.
  • the EVA particles 2, the coupling agent, and the UV stabilizer are mixed well in a certain ratio at atmospheric temperature (10 - 30°C), and then heated to obtain the first adhesive film.
  • the second adhesive layer with a thickness of 30 ⁇ is prepared on one surface of the polyester resin by using the EVA particles 1. Then, the prepared first adhesive film with a thickness of 30 ⁇ is coated on the other surface of the polyester resin. Finally, the prepared 140 ⁇ crosslinked anti-UV EVA film is coated on the first adhesive film to obtain a sample of the electrode isolating structure.
  • the anti-UV performance of the electrode isolating structure is evaluated by "ultraviolet irradiation test”; the adhesive performance of the electrode isolating structure is evaluated by “peel strength test”; and the hydrothermal aging performance of the electrode isolating structure is evaluated by “hydrothermal aging test”.
  • the prepared sample of the electrode isolating structure is placed in an accelerated aging oven, with the crosslinked anti-UV EVA layer facing the ultraviolet irradiation lamp source.
  • the HUNTERLAB instrument is used to measure the yellowness index (YI) of the electrode isolating structure in accordance with ASTM E313, with the ultraviolet irradiation being totaled to 150 kWh/m 2 . It is generally considered that when YI is less than 10, the anti-UV performance of the electrode isolating structure satisfies the requirements; when YI is less than 5, the anti-UV performance of the electrode isolating structure is good; when YI is less than 3, the anti-UV performance of the electrode isolating structure is very good.
  • the glass, encapsulating EVA, solar cells, and the sample of the electrode isolating structure prepared in accordance with the present invention are laminated in sequence and then encapsulated. Then, the INSTRON testing instrument is used to measure the peel strength between the electrode isolating structure and the solar cells in accordance with the ASTM D903 standard.
  • the glass, encapsulating EVA, busbar, and the sample of the electrode isolating structure prepared in accordance with the present invention are laminated in sequence and then encapsulated. Then, the INSTRON testing instrument is used to measure the peel strength between the electrode isolating structure and the busbar in accordance with the ASTM D903 standard.
  • the glass, encapsulating EVA, busbar, solar cells, and the sample of the electrode isolating structure prepared in accordance with the method of the present invention are laminated in sequence as shown in Fig. 1 and then encapsulated to obtain samples of the solar cell assembly.
  • the samples of the solar cell assembly are placed respectively in aging ovens with humidity being 85% and temperature being 85°C. Visually observe the solar cell assembly to see if there are any unpleasing appearances such as bumps or delaminations at the electrode isolating structure, especially at the overlapping regions of the solder points of the busbar with the he electrode isolating structure.
  • hydrothermal aging performance is not good; if there is no unpleasing appearance such as bumps or delaminations, then the hydrothermal aging performance is qualified.
  • EVA particles 3 1.0 wt.% peroxide crosslinking agent 1, 1.0 wt.% coupling agent 1, 1.0 wt.% UV absorbent, and 0.5 wt.% UV stabilizer were used to prepare the crosslinked anti-UV EVA layer in accordance with the preparing method of the present invention, with the thickness of the layer being 140 ⁇ .
  • 98.5 wt.% EVA particles 2, 1.0 wt.% coupling agent 1 and 0.5 wt.% UV stabilizer were used to prepare the first EVA layer having a thickness of 30 ⁇ .
  • PET was used as the polyester resin layer, and EVA particles 1 were used as the material of the second EVA layer.
  • Example 1 A sample of the electrode isolating structure of Example 1 was prepared in accordance with the preparing method of the present invention.
  • the sample of Example 1 was tested in accordance with the testing methods of the present invention, and the results of the tests are reported in Table 4.
  • Example 1 The materials and the preparing method set forth Example 1 were used, with the difference being that the percentages of the components for the crosslinked anti-UV EVA layer were different. See Table 3 for details. Samples of the electrode isolating structures of Examples 2-7 were prepared respectively in accordance with the preparing method of the present invention. The samples of Examples 2-7 were tested respectively in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • Example 4 Different from Example 4, the peroxide crosslinking agent 2 and the coupling agent 2 were used in the crosslinked anti-UV EVA layer, with the remaining materials and the percentages of each material being the same as in Example 4.
  • Example 8 A sample of the electrode isolating structure of Example 8 was prepared in accordance with the preparing method of the present invention.
  • the sample of Example 8 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • the peroxide crosslinking agent 2 was used in the crosslinked anti-UV EVA layer and PC was used as the polyester resin layer, with the remaining materials and the percentages of each material being the same as in Example 4.
  • Example 9 A sample of the electrode isolating structure of Example 9 was prepared in accordance with the preparing method of the present invention.
  • the sample of Example 9 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • PEN was selected as the polyester resin layer, with the remaining materials and the percentages of each material being the same as in Example 9.
  • Example 10 A sample of the electrode isolating structure of Example 10 was prepared in accordance with the preparing method of the present invention.
  • the sample of Example 10 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • Example 4 Different from Example 4, the acrylic coating was used as the first adhesive layer.
  • the materials and formulations of the crosslinked anti-UV EVA layer, the polyester resin layer and the second adhesive layer were the same as in Example 4.
  • the method of preparation of the crosslinked anti-UV EVA was the same as Example 4.
  • Example 11 The acrylic coating, a 3 ⁇ thick dry film, was first coated on the PET; then the prepared 170 ⁇ thick crosslinked anti-UV EVA film was coated on the PET with the coating. Finally, the other side of the PET layer was combined with a 30 ⁇ thick second adhesive layer to obtain a sample of the electrode isolating structure of Example 11.
  • the sample of Example 11 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • EVA particles 3 were used as the experimental material in the crosslinked anti-UV EVA layer.
  • a sample of the electrode isolating structure of Comparative Example 1 was prepared in accordance with the preparing method of the present invention.
  • the sample of Comparative Example 1 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • Example 4 Different from Example 4, the non-peroxide crosslinking agent and the coupling agent 1 were used in the crosslinked anti-UV EVA layer, with the remaining materials and the percentages of each material being the same as in Example 4.
  • a sample of the electrode isolating structure of Comparative Example 2 was prepared in accordance with the preparing method of the present invention.
  • the sample of Comparative Example 2 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
  • Example 1 The materials and the preparing method set forth in Example 1 were used, with the difference being that the percentages of the components for the crosslinked anti-UV EVA layer were different. See Table 3 for details.
  • the anti-UV performance of the electrode isolating structure of the present invention is in accordance with the requirements; the adhesion between the electrode isolating structure and the solar cells as well as the busbars is in accordance with the requirements; and the hydrothermal aging performance of the electrode isolating structure is also in accordance with the requirements.
  • the inventors have found that both the anti-UV performance and the adhesion of the electrode isolating structure can be improved by adding the crosslinked anti-UV EVA layer to a prior art electrode isolating structure, and with the synergistic effects shown among EVA particles, the peroxide crosslinking agent, the coupling agent, the UV absorbent, and the UV stabilizer in the crosslinked anti-UV EVA laye.
  • a high amount of the peroxide crosslinking agent (such as, Comparative Examples 3-5) is most likely to lead to a remnant, resulting in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure upon lamination and hydrothermal aging of the solar cell assembly, i.e., not in accordance with the requirements. Therefore, to ensuer that the electrode isolating structure has a certain level of hydrothermal aging resistant performance, the amount of the peroxide crosslinking agent should be less than 2%.
  • the addition of the non-peroxide crosslinking agent to the crosslinked anti-UV EVA layer to replace the peroxide crosslinking agent may increase the adhesive strength of the electrode isolating structure to some extent, the adhesive performance of the non-peroxide crosslinking agent is far inferior to that by adding the peroxide crosslinking agent. Additionally, upon lamination and hydrothermal aging of the solar cell assembly, the addition of the non-peroxide crosslinking agent may result in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure, which again is not in accordance with the requirements.
  • the yellowing index of the electrode isolating structure can be smaller than 5 under the UV irradiation intensity of 150 kWh/m 2 .
  • the yellowing index of the electrode isolating structure without addition of the UV absorbent and the UV stabilizer would be up to 30 or higher.
  • the optimal technical effects can be achieved in the most economical way.
  • the first adhesive layer may also be selected to be a weather resistant acrylic coating layer (such as Example 11); and the electrode isolating structure thus obtained can also meet the requirements of the anti-UV performance, the adhesive performance, and the hydrothermal aging resistant performance of the present invention.
  • the peel strength between the crosslinked anti-UV EVA layer and the polyester resin layer of the electrode isolating structure is inferior to the peel strength of the case when the first adhesive layer is selected as the ethylene vinyl acetate (EVA) particles-containing coating layer; and the cost in the former case would also be relatively high.
  • EVA ethylene vinyl acetate

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Abstract

The present invention provides an electrode isolating structure for a solar cell assembly, the electrode isolating structure comprising a crosslinked anti-UV EVA layer, a first adhesive layer, a polyester resin layer, and a second adhesive layer. When used, the anti-UV performance and hydrothermal aging resistant performance of the electrode isolating structure provided in the present invention are improved, solving the technical problem of the electrode isolating structure becoming yellow over time due to UV irradiation, which in turn affect the stability and appearance of the solar cell assembly. Additionally, the adhesion between the electrode isolating structure and the solar cells as well as busbars is improved, thereby solving the technical problem of the appearance defects of the electrode isolating structure such as de lamination occuring at the solar cells and solder points.

Description

AN ELECTRODE ISOLATING STRUCTURE AND A SOLAR CELL ASSEMBLY
FIELD OF THE INVENTION
The present invention relates to the field of solar cell assemblies, in particular, to an electrode isolating structure that can be used in a solar cell assembly, and a solar cell assembly comprising the electrode isolating structure.
BACKGROUND ART
As shown in Fig. 1, a solar cell assembly typically comprises a glass 2, two EVA layers 3, solar cells 4 encapsulated between the two EVA layers 3, and a back plate 5. In order to prevent the positive electrode 6 and the negative electrode 7 from contacting and causes a short circuit, an electrode isolating structure 8 is typically provided between the positive electrode 6 and the negative electrode 7. In order to increase the power of the solar cell assembly, a UV-transmittant encapsulating EVA material may be selected as the EVA layers 3. However, this design would result in yellowing of the electrode isolating structure 8 encapsulated in the EVA layers 3 due to UV irradiation, which may affect the stability and appearance of the solar cell assembly. Additionally, tin slag stuffing often occurs at the joints of the positive and negative busbars and the solder strip, which results in oversized solder points between the solder strip and the busbars; and the electrode isolating structure 8 would most likely be subjected to delamination in the process of hydrothermal aging.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide an electrode isolating structure for a solar cell assembly. The electrode isolating structure not only is weather resistant (anti-UV, hydrothermal aging resistant), but it also improves the adhesion between the electrode isolating structure and the solar cells and the adhesion between the electrode isolating structure and the busbars.
According to an aspect of the present invention, an electrode isolating structure is provided. The electrode isolating structure comprises: a crosslinked anti-UV EVA layer comprising a coupling agent, a UV absorbent, a UV stabilizer, ethylene vinyl acetate (EVA) particles, and a peroxide crosslinking agent in an amount of less than 2% by weight; a first adhesive layer selected from one or a combination of the following: an EVA particles-containing coating, an acrylic coating, a fluroresin coating, a polyurethane coating, an epoxy resin coating; a polyester resin layer; and a second adhesive layer comprising ethylene vinyl acetate (EVA) particles.
According to some embodiments, the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer comprise vinyl acetate in an amount of from 5% to 45%. According to some embodiments, the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer have a melt flow index (MFI) greater than 10.
According to some embodiments, the crosslinked anti-UV EVA layer is comprised of the peroxide crosslinking agent in an amount of from 0.5 wt.% to 1.5 wt.%, the coupling agent in an amount of from 0.5 wt.% to 1.5 wt.%, the UV absorbent in an amount of from 0 to 5 wt.%, the UV stabilizer in an amount of from 0 to 5 wt.%, and the ethylene vinyl acetate (EVA) particles in an amount of from 90 wt.% to 99 wt.%.
Preferably, the coupling agent is selected from silane coupling agents or titanate coupling agents.
Preferably, the crosslinked anti-UV EVA layer has a thickness of 50 - 500 μιη.
According to some embodiments, the first adhesive layer is an ethylene vinyl acetate (EVA) particles- containing coating, wherein the ethylene vinyl acetate (EVA) particles comprise vinyl acetate in an amount offrom 5% to 45%.
Preferably, the first adhesive layer is comprised of the ethylene vinyl acetate (EVA) particles in an amount of from 95 wt.% to 99 wt.%, a UV stabilizer in an amount of from 0 to 5 wt.%, and a coupling agent in an amount of from 0 to 5 wt.%.
According to some embodiments, the ethylene vinyl acetate (EVA) particles in the first adhesive layer have a melt flow index in the range of 10 - 50.
According to some embodiments, the ethylene vinyl acetate (EVA) particles in the second adhesive layer have a melt flow index in the range of 2 - 10.
According to some embodiments, the polyester resin layer comprises one or more of: polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polybutylene terephthalate (PBT), polymethylmethacrylate (PMMA).
When used, the anti-UV performance and hydrothermal aging resistant performance of the electrode isolating structure provided in the present invention are improved; the adhesion of the electrode isolating structure with both the solar cells and the busbars is also improved. As a result, the present invention solves the technical problem of the electrode isolating structure becoming yellow over time due to UV irradiation, which in turn may affect the stability and appearance of the solar cell assembly; further, the present invention also solves the problem of appearance defects of the electrode isolating structure such as delamination that may occur at the solder points.
According to another aspect of the present invention, a solar cell assembly comprising the electrode isolating structure of this invention is also provided. BRIEF DESCRIPTION OF THE DRAWINGS
In order to make the above and other objectives, features, and advantages of the present invention more apparent and readily understood, the present invention will be further explained below with the accompanying drawings and embodiments. A person skilled in the art would appreciate that the drawings are intended to schematically illustrate the preferred embodiments of the present invention, and the parts in the drawings are not drawn to scale.
Fig. 1 is a schematic diagram of the structure of a solar cell assembly;
Fig. 2 is a schematic diagram of the electrode isolating structure in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Some embodiments in accordance with the present invention will be described below in more detail by referring to the accompanying drawings. It should be understood that, without departing from the scope and spirit of the present invention, a person skilled in the art would be able to envisage other various embodiments based on the teachings provided herein, and modify the same. Therefore, the embodiments set forth below are for illustration rather than limiting.
Unless otherwise indicated, all numbers used in this Description and the Claims for presenting size, amounts, and physical properties of the features should be understood as being modified by the term "about". Accordingly, unless indicated to the contrary, the numerical values set forth in this Description and the Claims are approximate values, and based on the teachings of the present invention, a person skilled in the art would be able to change such approximate values appropriately, so as to obtain desired properties. A numerical range represented by endpoints should include all numbers in the range; for example, the range 1 to 5 includes 1, 1.1, 1.3, 1.5, 2, 2.75, 3, 3.80, 4 and 5, etc.
Unless otherwise indicated, all materials used in the embodiments are commercially available industrial products.
Definitions
Melt Flow Index (MFI): a flow rate of a melt measured under a load of 2.16 Kg at 190°C according to the test method provided in ASTM D 1238.
Electrode Isolating Structure
As shown in Fig. 2, the electrode isolating structure 8 comprises, in order from top to bottom: a crosslinked anti-UV EVA layer 81, a first adhesive layer 82, a polyester resin layer 83, and a second adhesive layer 84. In the present invention, the crosslinked anti-UV EVA layer 81 comprises a peroxide crosslinking agent, a coupling agent, a UV absorbent, a UV stabilizer, and ethylene vinyl acetate (EVA) particles, wherein the peroxide crosslinking agent is in an amount of less than 2% by weight; the first adhesive layer may be selected as an ethylene vinyl acetate (EVA) particles-containing coating; the second adhesive layer comprises ethylene vinyl acetate (EVA) particles.
In particular, the crosslinked anti-UV EVA layer 81 has anti-UV properties, adhesive properties and hydrothermal aging resistant properties, and may be comprised of the peroxide crosslinking agent in an amount of from 0.5 wt.% to 1.5 wt.%, the coupling agent in an amount of from 0.5 wt.% to 1.5 wt.%, the UV absorbent in an amount of from 0 to 5 wt.%, the UV stabilizer in an amount of from 0 to 5 wt.%, and the ethylene vinyl acetate (EVA) particles in an amount of from 90 wt.% to 99 wt.%. The thickness of the crosslinked anti-UV EVA layer 81 is in the range of from 50 μιη to 500 μιη, and preferably, is 140 μιη.
The inventors have found from the research that addition of the peroxide crosslinking agent can improve the crosslinking properties of the electrode isolating structure. However, a too high amount of the peroxide crosslinking agent is quitely likely to lead to a remnant, resulting in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure upon lamination and hydrothermal aging of the solar cell assembly. To ensure that the electrode isolating structure has good crosslinking performance, anti-UV performance, and hydrothermal aging resistant performance, the components in the crosslinked anti-UV EVA layer should show synergistic effects, and the crosslinked anti-UV EVA layer should interact with other layers of the electrode isolating structure. Preferably, the peroxide crosslinking agent is in an amount of from 0.5 wt.% to 1.5 wt.%; the coupling agent is in an amount of from 0.5 wt.% to 1.5 wt.%; the UV absorbent is in an amount of from 0.1 wt.% to 2 wt.%; the UV stabilizer is in an amount of from 0.1 wt.% to 2 wt.%; and the ethylene vinyl acetate (EVA) particles are in an amount of from 93 wt.% to 97 wt.%.
Preferably, in the crosslinked anti-UV EVA layer, the coupling agent may be a silane coupling agent (for example, KH550, KH560, KH570), a titanate coupling agent, or the like. The UV absorbent may be selected from salicylates, benzophenones, benzotriazoles, substituted acrylonitriles, or triazines. For example, benzophenone UV absorbents may include UV-9 (2-hydroxy-4- methoxybenzophenone), UV-531 (2-hydroxy-4-n-octoxy-benzophenone), UV-24 (2,2'-dihydroxy-4- methoxybenzophenone), and the like; the benzotriazole UV absorbents may include UV-326 ((2'- hydroxy-3 '-tertbutyl-5 '-methylphenyl)-5-chloro-benzotriazole), UV-P (2-(2'-Hydroxy-5 '- methylphenyl)benzotriazole, and the like; and the triazine UV absorbents may include triazine- 5(2,4,6-tri(2'-hydroxy-4'-n-octoxyphenyl)-l,3,5-triazine, and the like. The UV stabilizer may include hindered amines and the like. Typical UV stabilizers may include, such as TINUVIN 622, TINUVIN 770, TINUVIN 783, TINUVIN P and TINUVIN 788 from BASF; CYASORB UV 1 164, CYASORB UV 2126, CYASORB UV 3346, CYASORB UV 3853, and CYASORB THT series of products from Cytec. Preferably, the crosslinking agent may be organic peroxide initiators, such as benzoyl peroxide (BPO), tert-amyl perbenzoate (TAPA), tert-butyl peroxy-3,3,5-trimethylhexanoate (TBPMH), tert-butyl peroxybenzoate (TBPB), tert-butyl peroxy-2-ethylhexyl carbonate (TBEC), dicumyl peroxide (DCP), tert-butyl cumyl peroxide (TBCP), and the like. Preferably, the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is greater than 10, wherein the vinyl acetate (VA) is in an amount of from 5% to 45%, which facilitates the crosslinking. For example, PV1300, PV1400Z from DuPont and PV280 from Samsung Total may be used.
The first adhesive layer 82 has anti-UV and adhesive properties, and may be comprised of the ethylene vinyl acetate (EVA) particles in an amount of from 95 wt.% to 99 wt.%; a UV stabilizer in an amount of from 0 to 5 wt.%; and a coupling agent in an amount of from 0 to 5 wt.%. The thickness of the first adhesive layer 82 is in the range of from 5 μιη to 100 μιη, and preferably, is 30 μιη.
In the first adhesive layer, the coupling agent used may be a silane coupling agent or a titanate coupling agent. The UV stabilizer may be selected as TINUVIN 622, TINUVIN 770 from BASF, and
CYASORB UV 1164, CYASORB UV 2126 and CYASORB THT series of products from Cytec.
Preferably, the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is greater than 10; and more preferably, the MFI is in the range of from 10 to 50, wherein the vinyl acetate (VA) is in an amount of from 5% to 45%. For example, TAISOX 7660M EVA from Formosa Plastics may be selected.
Additionally, an acrylic coating, a fluroresin coating, a polyurethane coating, an epoxy resin coating, or various coupling agent coatings may be used in the first adhesive layer; and the thickness of the first adhesive layer may be in the range of from 1 μιη to 20 μιη.
The thickness of the polyester resin layer 83 may be in the range of from 50 μιη to 250 μιη. Preferably, the polyester resin layer may be a white polyethylene terephthalate (PET); and more preferably, it may be a hydrolysis resistant PET having good weather resistant properties. For example, the PET products under the trade name DS 11 from Eastern Material Technologies may be used. The thickness of the layer is preferably 100 μιη. In addition to the above, polycarbonate (PC), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), and polymethylmethacrylate (PMMA) may also be used as the polyester resin layer.
The second adhesive layer 84 has adhesive and fixing properties, and the thickness thereof is in the range of from 5 μπι to 100 μπι, with 30 μπι being preferable. Preferably, the melt flow index (MFI) of the ethylene vinyl acetate (EVA) particles is less than 10, with 2-10 of MFI being more preferable; the vinyl acetate (VA) is in an amount of from 5% to 45%. For example, 51 10J EVA from Yangtze BASF may be used.
As shown in Fig. 1, the electrode isolating structure of the present invention may be disposed between the positive electrode 6 and the negative electrode 7 of adjacent solar cells in the solar cell assembly to isolate the positive and the negative electrodes. When the solar cell assembly is hit directly by the sunlight, the crosslinked anti-UV EVA layer and the first adhesive layer of the electrode isolating structure of the present invention can keep out ultraviolet light effectively; and the crosslinked anti- UV EVA layer can provide much better adhesion and hydrothermal aging resistant performance. When the electrode isolating structure of the present invention is used in a solar cell assembly, the solar cell assembly is much safer in use with long service life. The structure provides strong isolation between the positive electrode and the negative electrode, so as to protect the solar cell assembly. Examples
The Examples and Comparative Examples set forth below will facilitate the understanding of the present invention; however, such Examples and Comparative Examples are merely used to illustrate the present invention, and shall not be interpreted as limiting the scope thereof. Unless otherwise indicated, all parts and percentages used herein are by weight.
The materials used in the Examples and Comparative Examples of the present invention are shown in
Table 1.
Table 1
Figure imgf000007_0001
Preparing Method
An illustrative method of preparation of the electrode isolating structure of the present invention is described below.
In order to prepare the crosslinked anti-UV EVA layer of the present invention, the EVA particles 3, the peroxide crosslinking agent, the coupling agent, the UV absorbent, and the UV stabilizer are mixed well in a certain ratio at atmospheric temperature (10 - 30°C), and then heated to obtain the crosslinked anti-UV EVA film.
Similarly, the EVA particles 2, the coupling agent, and the UV stabilizer are mixed well in a certain ratio at atmospheric temperature (10 - 30°C), and then heated to obtain the first adhesive film.
The second adhesive layer with a thickness of 30 μιη is prepared on one surface of the polyester resin by using the EVA particles 1. Then, the prepared first adhesive film with a thickness of 30 μιη is coated on the other surface of the polyester resin. Finally, the prepared 140 μιη crosslinked anti-UV EVA film is coated on the first adhesive film to obtain a sample of the electrode isolating structure.
In this invention, the anti-UV performance of the electrode isolating structure is evaluated by "ultraviolet irradiation test"; the adhesive performance of the electrode isolating structure is evaluated by "peel strength test"; and the hydrothermal aging performance of the electrode isolating structure is evaluated by "hydrothermal aging test".
Ultraviolet Irradiation Test
In accordance with ASTM G154 cycle 1, the prepared sample of the electrode isolating structure is placed in an accelerated aging oven, with the crosslinked anti-UV EVA layer facing the ultraviolet irradiation lamp source.
The HUNTERLAB instrument is used to measure the yellowness index (YI) of the electrode isolating structure in accordance with ASTM E313, with the ultraviolet irradiation being totaled to 150 kWh/m2. It is generally considered that when YI is less than 10, the anti-UV performance of the electrode isolating structure satisfies the requirements; when YI is less than 5, the anti-UV performance of the electrode isolating structure is good; when YI is less than 3, the anti-UV performance of the electrode isolating structure is very good.
Peel Strength Test
The glass, encapsulating EVA, solar cells, and the sample of the electrode isolating structure prepared in accordance with the present invention are laminated in sequence and then encapsulated. Then, the INSTRON testing instrument is used to measure the peel strength between the electrode isolating structure and the solar cells in accordance with the ASTM D903 standard. The glass, encapsulating EVA, busbar, and the sample of the electrode isolating structure prepared in accordance with the present invention are laminated in sequence and then encapsulated. Then, the INSTRON testing instrument is used to measure the peel strength between the electrode isolating structure and the busbar in accordance with the ASTM D903 standard.
It is generally considered that when the peel strength is greater than 5 N/cm, the adhesion of the electrode isolating structure satisfies the requirements; when the peel strength is greater than 10 N/cm, the adhesion of the electrode isolating structure is very good. In the test, if the solar cells themselves are broken while the electrode isolating structure and the solar cells are still kept unseparated, then the adhesion of the electrode isolating structure would be deemed as excellent. Hydrothermal Aging Test
The glass, encapsulating EVA, busbar, solar cells, and the sample of the electrode isolating structure prepared in accordance with the method of the present invention are laminated in sequence as shown in Fig. 1 and then encapsulated to obtain samples of the solar cell assembly. The samples of the solar cell assembly are placed respectively in aging ovens with humidity being 85% and temperature being 85°C. Visually observe the solar cell assembly to see if there are any unpleasing appearances such as bumps or delaminations at the electrode isolating structure, especially at the overlapping regions of the solder points of the busbar with the he electrode isolating structure. It is generally considered that if any unpleasing appearances such as bumps or delaminations are present, the hydrothermal aging performance is not good; if there is no unpleasing appearance such as bumps or delaminations, then the hydrothermal aging performance is qualified.
Example 1
96.5 wt.% EVA particles 3, 1.0 wt.% peroxide crosslinking agent 1, 1.0 wt.% coupling agent 1, 1.0 wt.% UV absorbent, and 0.5 wt.% UV stabilizer were used to prepare the crosslinked anti-UV EVA layer in accordance with the preparing method of the present invention, with the thickness of the layer being 140 μπι. 98.5 wt.% EVA particles 2, 1.0 wt.% coupling agent 1 and 0.5 wt.% UV stabilizer were used to prepare the first EVA layer having a thickness of 30 μπι. PET was used as the polyester resin layer, and EVA particles 1 were used as the material of the second EVA layer.
A sample of the electrode isolating structure of Example 1 was prepared in accordance with the preparing method of the present invention. The sample of Example 1 was tested in accordance with the testing methods of the present invention, and the results of the tests are reported in Table 4.
Examples 2-7
The materials and the preparing method set forth Example 1 were used, with the difference being that the percentages of the components for the crosslinked anti-UV EVA layer were different. See Table 3 for details. Samples of the electrode isolating structures of Examples 2-7 were prepared respectively in accordance with the preparing method of the present invention. The samples of Examples 2-7 were tested respectively in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Example 8
Different from Example 4, the peroxide crosslinking agent 2 and the coupling agent 2 were used in the crosslinked anti-UV EVA layer, with the remaining materials and the percentages of each material being the same as in Example 4.
A sample of the electrode isolating structure of Example 8 was prepared in accordance with the preparing method of the present invention. The sample of Example 8 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Example 9
Different from Example 4, the peroxide crosslinking agent 2 was used in the crosslinked anti-UV EVA layer and PC was used as the polyester resin layer, with the remaining materials and the percentages of each material being the same as in Example 4.
A sample of the electrode isolating structure of Example 9 was prepared in accordance with the preparing method of the present invention. The sample of Example 9 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Example 10
Different from Example 9, PEN was selected as the polyester resin layer, with the remaining materials and the percentages of each material being the same as in Example 9.
A sample of the electrode isolating structure of Example 10 was prepared in accordance with the preparing method of the present invention. The sample of Example 10 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Example 11
Different from Example 4, the acrylic coating was used as the first adhesive layer. The materials and formulations of the crosslinked anti-UV EVA layer, the polyester resin layer and the second adhesive layer were the same as in Example 4. The method of preparation of the crosslinked anti-UV EVA was the same as Example 4.
The acrylic coating, a 3 μιη thick dry film, was first coated on the PET; then the prepared 170 μπι thick crosslinked anti-UV EVA film was coated on the PET with the coating. Finally, the other side of the PET layer was combined with a 30 μπι thick second adhesive layer to obtain a sample of the electrode isolating structure of Example 11. The sample of Example 11 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Comparative Example 1
Different from Example 1, only EVA particles 3 were used as the experimental material in the crosslinked anti-UV EVA layer.
A sample of the electrode isolating structure of Comparative Example 1 was prepared in accordance with the preparing method of the present invention. The sample of Comparative Example 1 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Comparative Example 2
Different from Example 4, the non-peroxide crosslinking agent and the coupling agent 1 were used in the crosslinked anti-UV EVA layer, with the remaining materials and the percentages of each material being the same as in Example 4.
A sample of the electrode isolating structure of Comparative Example 2 was prepared in accordance with the preparing method of the present invention. The sample of Comparative Example 2 was tested in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
Comparative Examples 3-5
The materials and the preparing method set forth in Example 1 were used, with the difference being that the percentages of the components for the crosslinked anti-UV EVA layer were different. See Table 3 for details.
Samples of the electrode isolating structures of Comparative Examples 3-5 were prepared respectively in accordance with the preparing method of the present invention. The samples of Comparative Examples 3-5 were tested respectively in accordance with the testing methods of the present invention. The results of the tests are reported in Table 4.
The materials for the Examples and the Comparative Examples of the present invention are shown in Table 2.
The percentages of the components in the crosslinked anti-UV EVA layer of the Examples and the Comparative Examples of the present invention are shown in Table 3. Table 2
Figure imgf000012_0001
Figure imgf000013_0001
Table 3
Figure imgf000014_0001
The test results of the Examples and the Comparative Examples are provided in Table 4.
Table 4
Figure imgf000014_0002
Example 8 3.78 8.9 Yes 14.1 Qualified
Example 9 4.15 8.8 Yes 15.3 Qualified
Example 10 3.77 9.3 Yes 14.7 Qualified
Example 11 4.27 11.9 Yes 15.6 Qualified
Comparative No
Example 1 35.65 2.1 1.8 Not good
Comparative No
Example 2 4.43 5.1 5.8 Not good
Comparative Yes
Example 3 4.11 9.1 14.5 Not good
Comparative Yes
Example 4 3.97 8.4 16.4 Not good
Comparative Yes
Example 5 3.78 7.8 13.1 Not good
As shown in Table 4, the anti-UV performance of the electrode isolating structure of the present invention is in accordance with the requirements; the adhesion between the electrode isolating structure and the solar cells as well as the busbars is in accordance with the requirements; and the hydrothermal aging performance of the electrode isolating structure is also in accordance with the requirements.
The inventors have found that both the anti-UV performance and the adhesion of the electrode isolating structure can be improved by adding the crosslinked anti-UV EVA layer to a prior art electrode isolating structure, and with the synergistic effects shown among EVA particles, the peroxide crosslinking agent, the coupling agent, the UV absorbent, and the UV stabilizer in the crosslinked anti-UV EVA laye. However, a high amount of the peroxide crosslinking agent (such as, Comparative Examples 3-5) is most likely to lead to a remnant, resulting in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure upon lamination and hydrothermal aging of the solar cell assembly, i.e., not in accordance with the requirements. Therefore, to ensuer that the electrode isolating structure has a certain level of hydrothermal aging resistant performance, the amount of the peroxide crosslinking agent should be less than 2%.
Although the addition of the non-peroxide crosslinking agent to the crosslinked anti-UV EVA layer to replace the peroxide crosslinking agent may increase the adhesive strength of the electrode isolating structure to some extent, the adhesive performance of the non-peroxide crosslinking agent is far inferior to that by adding the peroxide crosslinking agent. Additionally, upon lamination and hydrothermal aging of the solar cell assembly, the addition of the non-peroxide crosslinking agent may result in an appearance defect such as bumps or delamination in the vicinity of the electrode isolating structure, which again is not in accordance with the requirements. When the amount of the UV absorbent is up to 2% in the crosslinked anti-UV EVA layer and the amount of the UV stabilizer is up to 0.7%, the yellowing index of the electrode isolating structure can be smaller than 5 under the UV irradiation intensity of 150 kWh/m2. However, the yellowing index of the electrode isolating structure without addition of the UV absorbent and the UV stabilizer (such as, Comparative Example 1) would be up to 30 or higher.
In particular, when the amount of the peroxide crosslinking agent is 1 wt.%, the mount of the coupling agent is 1 wt.%, the amount of the UV absorbent is 2 wt.%, the amount of the UV stabilizer is 0.7 wt.%, and the first adhesive layer is an ethylene vinyl acetate (EVA) particles-containing coating, the optimal technical effects can be achieved in the most economical way.
In this invention, the first adhesive layer may also be selected to be a weather resistant acrylic coating layer (such as Example 11); and the electrode isolating structure thus obtained can also meet the requirements of the anti-UV performance, the adhesive performance, and the hydrothermal aging resistant performance of the present invention. However, in practice, the peel strength between the crosslinked anti-UV EVA layer and the polyester resin layer of the electrode isolating structure is inferior to the peel strength of the case when the first adhesive layer is selected as the ethylene vinyl acetate (EVA) particles-containing coating layer; and the cost in the former case would also be relatively high.
The particular embodiments as set forth above illustrate merely the principle and effects of the present invention, rather than limiting the same. A person skilled in the art would understand that any variations and modifications made thereto would fall within the scope of the present invention without departing from the spirit and scope thereof. The scope of the present invention should be defined by the appended Claims.

Claims

1. An electrode isolating structure, comprising: a crosslinked anti-UV EVA layer, comprising a coupling agent, a UV absorbent, a UV stabilizer, ethylene vinyl acetate (EVA) particles, and a peroxide crosslinking agent in an amount of less than 2% by weight;
a first adhesive layer, selected from one or a combination of the following: an EVA particles-containing coating, an acrylic coating, a fluroresin coating, a polyurethane coating, an epoxy resin coating;
a polyester resin layer; and
a second adhesive layer, comprising ethylene vinyl acetate (EVA) particles.
2. The electrode isolating structure according to claim 1, wherein the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer comprise vinyl acetate in an amount of from 5% to 45%.
3. The electrode isolating structure according to claim 1 or 2, wherein the ethylene vinyl acetate (EVA) particles in the crosslinked anti-UV EVA layer have a melt flow index greater than 10.
4. The electrode isolating structure according to claim 1, wherein the crosslinked anti-UV EVA layer is comprised of the peroxide crosslinking agent in an amount of from 0.5 wt.% to 1.5 wt.%, the coupling agent in an amount of from 0.5 wt.% to 1.5 wt.%, the UV absorbent in an amount of from 0 to 5 wt.%, the UV stabilizer in an amount of from 0 to 5 wt.%, and the ethylene vinyl acetate (EVA) particles in an amount of from 90 wt.% to 99 wt.%.
5. The electrode isolating structure according to claim 4, wherein the coupling agent is selected from silane coupling agents or titanate coupling agents.
6. The electrode isolating structure according to claim 1, wherein the crosslinked anti-UV EVA layer has a thickness of from 50 μιη to 500 μιη.
7. The electrode isolating structure according to claim 1, wherein the first adhesive layer is an ethylene vinyl acetate (EVA) particles-containing coating, and wherein the ethylene vinyl acetate (EVA) particles comprise vinyl acetate in an amount of from 5% to 45%.
8. The electrode isolating structure according to claim 7, wherein the ethylene vinyl acetate (EVA) particles in the first adhesive layer have a melt flow index in the range of 10 - 50.
9. The electrode isolating structure according to claim 7, wherein the first adhesive layer is comprised of the ethylene vinyl acetate (EVA)particles in an amount of from 95 wt.% to 99 wt.%, a UV stabilizer in an amount of from 0 to 5 wt.%, and a coupling agent in an amount of from 0 to
5 wt.%.
10. The electrode isolating structure according to claim 1 or 2, wherein the ethylene vinyl acetate (EVA) particles in the second adhesive layer have a melt flow index in the range of 2 - 10.
1 1. The electrode isolating structure according to claim 1, wherein the polyester resin layer comprises one or more of: polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polybutylene terephthalate (PBT), and polymethylmethacrylate (PMMA).
A solar cell assembly, comprising the electrode isolating structure according to any one of claims
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