CN101177514B - 一种太阳能电池背板及其制备方法 - Google Patents
一种太阳能电池背板及其制备方法 Download PDFInfo
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- CN101177514B CN101177514B CN2007101852028A CN200710185202A CN101177514B CN 101177514 B CN101177514 B CN 101177514B CN 2007101852028 A CN2007101852028 A CN 2007101852028A CN 200710185202 A CN200710185202 A CN 200710185202A CN 101177514 B CN101177514 B CN 101177514B
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- fluoropolymer layer
- cell backboard
- resin
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Classifications
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Abstract
本发明涉及一种太阳能电池背板及其制备方法,该背板包括基材和含氟聚合物层,含氟聚合物层各组分按重量份数计为:含氟树脂25~45份;改性树脂1.5~3份;聚合物填料0.5~3份;无机填料0.1~1份;溶剂50~70份。本发明生产成本低,性能优良,其剥离强度高,阻水性能好,耐候性好;本发明提供的制备方法,工艺简单,可以实现连续工业化生产。
Description
技术领域
本发明涉及一种太阳能电池背板及其制备方法。
背景技术
作为传统电能生产方法的绿色替代方案,光伏电池组件被用来利用太阳光产生电能。光伏电池组件是由各种半导体元件***组装而成,因而必须加以保护以减轻环境作用如湿气、氧气和紫外线的影响和破坏。光伏电池组件通常采用的是在硅片两侧层压贴附玻璃或塑料膜保护层的结构。由于具有优良的强度、耐候性、抗紫外性和阻湿性能,用氟聚合物薄膜和聚酯(PET)薄膜层叠而成的背板在光伏电池组件中发挥着重要作用。传统的背板生产方式是将预先制造好的氟聚合物薄膜特别是聚氟乙烯(PVF)薄膜粘贴于聚酯(PET)基材上,典型的是在PET两侧贴附氟聚合物薄膜而形成“三明治”结构。当氟聚合物薄膜(如PVF)用作光伏电池组件背板时,它的性能明显地改善了组件的使用寿命,使组件保证使用寿命达到25年。
然而,预生产的氟哦聚合物薄膜与聚合物基底材料间紧密粘附,暴露在户外若干年后也不会脱开是很难实现的。此前采用的技术措施,如美国专利US3133854、US5139878和US6632518都描述了通过在贴附氟聚合物薄膜之前在基材上预涂底层或粘接层以得到耐久的层叠结构背板的方法。然而,这些方法都需要在真正的层叠步骤之前提供至少一个粘接层或底层和粘接层,然后在层叠步骤通过受热和压力作用完成层叠,因此,使用预生产的氟聚合物薄膜层叠的方法步骤繁多,成本较高。同时,由于预生产的氟聚合物薄膜必须有足够的厚度以满足在贴合及后处理程序过程中对其强度的要求,使得膜的实际厚度比为提供保护性能所需的厚度大,造成价格昂贵的氟树脂薄膜的浪费,提高了产品的成本。
发明内容
本发明所要解决的技术问题是提供一种太阳能电池背板,该背板不需要使用附加的底层或粘合剂层,其生产成本低,性能优良。
本发明要解决的另一技术问题是提供一种太阳能电池背板的制备方法,该方法工艺简单,可以实现连续工业化生产。
为解决上述技术问题,本发明所采用的技术方案是:
一种太阳能电池背板,包括基材和含氟聚合物层,所述含氟聚合物层的组分及其重量份数为:
含氟树脂 25~45份
改性树脂 1.5~3份
聚合物填料 0.5~3份
无机填料 0.1~1份
溶剂 50~70份。
上述太阳能电池背板,所述含氟树脂是偏氟乙烯、四氟乙烯、六氟丙烯的均聚物或它们的共聚物。
上述太阳能电池背板,所述改性树脂是用羧酸基、磺酸基、氮杂环丙烷基、异氰酸酯基、环氧基、胺基、羟基或活性亚甲基改性处理的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂。
上述太阳能电池背板,所述含氟聚合物层包括选自如下元素的氧化物的无机填料:钛、铝、锡或硅。
上述太阳能电池背板,所述溶剂是甲苯、丁酮、醋酸乙酯、醋酸丁酯中的一种或几种。
上述太阳能电池背板,所述含氟聚合物层的厚度为25~50μm。
一种太阳能电池背板的制备方法,在基材表面上涂布含氟聚合物层,固化得到太阳能电池背板。
一般用于太阳能电池背板的基材是聚酯,例如,它可以是聚对苯二甲酸乙二酯(PET)、聚萘二甲酸乙二酯PEN或它们的双层共挤的产物。根据用途不同,基材可以是透明、白色或黑色。
为了能够更好的体现出含氟聚合物的特性例如耐候性、耐溶剂性和阻隔性,用于本发明的含氟树脂可以是偏氟乙烯、四氟乙烯、六氟乙烯的均聚物或它们的共聚物,优选下列含氟树脂:
聚偏氟乙烯树脂;
聚偏氟乙烯-四氟乙烯树脂;
聚偏氟乙烯-六氟丙烯树脂;
聚偏氟乙烯-四氟乙烯-六氟丙烯树脂。
本发明的含氟聚合物层中含有改性树脂,通过使用这些改性树脂,可以明显提高氟聚合物涂层与基材之间的粘附力,达到无需使用额外的底层或粘接层也能保证氟聚合物涂层与基材之间粘接强度,满足25年以上使用寿命要求的目的。适合本发明的改性树脂是用羧酸基、磺酸基、氮杂环丙烷基、异氰酸酯基、环氧基、胺基、羟基、活性亚甲基或以上基团混合物进行改性处理的偏氟乙烯、四氟乙烯、六氟丙烯的均聚物或其中两种或三种的共聚物,优选下列改性树脂:
胺基改性聚偏氟乙烯-四氟乙烯-六氟丙烯树脂;
羟基改性聚偏氟乙烯-四氟乙烯-六氟丙烯树脂;
氮杂环丙烷基改性聚偏氟乙烯-四氟乙烯-六氟丙烯树指。
为了进一步提高含氟聚合物层的强度,本发明的含氟聚合物层中含有聚合物填料,这些聚合物填料可以是丙烯酸酯聚合物颗粒、乙烯基聚合物颗粒、含氟乙烯基聚合物颗粒、聚酰胺颗粒等,其平均粒径为1~4μm,颗粒可以是规则的球形,也可以是片状、棒状或其它不规则形状,颗粒的尺寸可以是均匀分布也可以是不规则分布的。
为了增强含氟聚合物层的耐候性、耐溶剂性和阻隔性,本发明的含氟聚合物层中含有无机填料,这些无机填料选自如下元素的氧化物中的一种或几种:钛、铝、锡和硅,例如石英颗粒、云母颗粒、二氧化钛颗粒。
适合本发明的溶剂可以是甲苯、丁酮、醋酸乙酯、醋酸丁酯中的一种或几种。
在本发明的含氟聚合物薄膜中,先制备含氟聚合物层的涂布液,该涂布液含有以上所列的含氟树脂,改性树脂,聚合物填料,无机填料,并通过溶剂将组合物粘度调整到适宜涂布的范围。含氟聚合物层的组分及其重量份数为:
含氟树脂 25~45份
改性树脂 1.5~3份
聚合物填料 0.5~3份
无机填料 0.1~1份
溶剂 50~70份
本发明提供的太阳能电池背板,可以通过下述方法制备:
将基材展开,在它的表面上涂布含氟聚合物层,涂布之后通过固化得到太阳能电池背板。
本发明方法采取的固化方法包括通过紫外线照射使含氟聚合物交联固化或通过采用X射线、钴60、静电加速器和大功率电子直线加速器等作为辐照源由高能射线引发含氟聚合物交联固化。
本发明中,含氟聚合物层可以通过浸涂法、气刀涂布法、刮刀涂布法、凹版涂布法、狭缝涂布法等方法涂布在基材上。
太阳能电池背板的厚度为25~50μm,优选30~40μm。
有益效果
本发明得到太阳能电池背板,由于不需要使用附加的底层或粘合剂层,其生产成本低,性能优良;其剥离强度高,阻水性能好,耐候性好。
本发明提供的制备方法,工艺简单,可以实现连续工业化生产。
具体实施方式
下面通过具体实施例对本发明作进一步说明,但不限于此。
实施例1
聚偏氟乙烯(Aldrich制) 25份
羟基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂
(中国乐凯胶片集团公司制) 3份
聚四氟乙烯(Solvay Solexis制) 2份
二氧化钛粉(DU PONT制) 0.2份
丁酮 20份
醋酸乙酯 50份
在装有搅拌装置的容器中加入20份丁酮、50份的醋酸乙酯,开动搅拌,将25份的聚偏氟乙烯、3份的羟基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂、、2份的聚四氟乙烯粉和0.2份的二氧化钛粉依次加入溶剂中,搅拌60分钟,制得含氟聚合物层涂布液。通过刮刀涂布法将涂布液涂布在PET基材上,热风干燥,得到含氟聚合物层厚度为25μm的太阳能电池背板,测其性能。
类似地,将一面涂好含氟聚合物层的基材翻转,按以上步骤在基材的另一面涂布得到第二个含氟聚合物层。
实施例2
聚四氟乙烯(Aldrich制) 40份
胺基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂
(中国乐凯胶片集团公司制) 2份
聚酰胺颗粒(Solvay Solexis制) 3份
石英颗粒(DU PONT制) 0.3份
醋酸丁酯 55份
在装有搅拌装置的容器中加入55份的醋酸丁酯,开动搅拌,将40份的聚四氟乙烯、2份的胺基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂、3份的聚酰胺颗粒和0.3份的石英颗粒依次加入溶剂中,搅拌50分钟,制得含氟聚合物层涂布液。通过浸涂法将涂布液涂布在PEN基材上,热风干燥,得到含氟聚合物层厚度为40μm的太阳能电池背板,测其性能。
类似地,将一面涂好含氟聚合物层的基材翻转,按以上步骤在基材的另一面涂布得到第二个含氟聚合物层。
实施例3
聚偏氟乙烯-六氟丙烯(3M Dyneon制) 45份
氮杂环丙烷基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂
(中国乐凯胶片集团公司制) 2.5份
聚丙烯酸酯聚合物颗粒(Solvay Solexis制) 2.5份
云母颗粒(DU PONT制) 0.1份
甲苯 50份
在装有搅拌装置的容器中加入50份的甲苯,开动搅拌,将45份的聚偏氟乙烯-六氟丙烯、2.5份的氮杂环丙烷基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂、2.5份的聚丙烯酸酯聚合物颗粒和0.1份的云母颗粒依次加入溶剂中,搅拌80分钟,制得含氟聚合物层涂布液。通过凹版涂布法将涂布液涂布在PET基材上,紫外线照射,得到含氟聚合物层厚度为50μm的太阳能电池背板,测其性能。
类似地,将一面涂好含氟聚合物层的基材翻转,按以上步骤在基材的另一面涂布得到第二个含氟聚合物层。
实施例4
聚四氟乙烯-六氟丙烯(3M Dyneon制) 30份
磺酸基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂
(中国乐凯胶片集团公司制) 1.5份
聚四氟乙烯粉(Solvay Solexis制) 0.5份
二氧化钛粉(DU PONT制) 1份
醋酸乙酯 30份
醋酸丁酯 35份
在装有搅拌装置的容器中加入30份醋酸乙酯、35份醋酸丁酯,开动搅拌,将30份的聚四氟乙烯-六氟丙烯、1.5份的磺酸基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂、0.5份的聚四氟乙烯粉和1份的二氧化钛粉依次加入溶剂中,搅拌60分钟,制得含氟聚合物层涂布液。通过刮刀涂布法将涂布液涂布在PEN基材上,热辐射固化,得到含氟聚合物层厚度为30μm的太阳能电池背板,测其性能。
类似地,将一面涂好含氟聚合物层的基材翻转,按以上步骤在基材的另一面涂布得到第二个含氟聚合物层。
实施例5
聚偏氟乙烯-四氟乙烯-六氟丙烯
(中国乐凯胶片集团公司制) 45份
羧酸基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂
(中国乐凯胶片集团公司制) 3.0份
聚酰胺颗粒(Solvay Solexis制) 1.5份
云母颗粒(DU PONT制) 0.5份
醋酸丁酮 50份
在装有搅拌装置的容器中加入50份醋酸丁酮,开动搅拌,将45份的聚偏氟乙烯-四氟乙烯-六氟丙烯、3份的羧酸基改性的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂、1.5份的聚酰胺颗粒和0.5份的云母颗粒粉依次加入溶剂中,搅拌60分钟,制得含氟聚合物层涂布液。通过刮刀涂布法将涂布液涂布在PET基材上,热辐射固化,得到含氟聚合物层厚度为50μm的太阳能电池背板,测其性能。
类似地,将一面涂好含氟聚合物层的基材翻转,按以上步骤在基材的另一面涂布得到第二个含氟聚合物层。
对比例
在厚度为75μm的PET基材(中国乐凯胶片集团公司制)上两面分别涂布热固性粘合剂(Hexion制)后热压贴合厚度为38μm的PVF薄膜(DU PONT制),得到传统方式制造的背板对比样品。
水气透过率(g/m<sup>2</sup>·24h) | 耐候性测试 | 涂层附着力测试(脱落面积) | |
实施例1 | 1.98 | 通过 | 0 |
实施例2 | 2.03 | 通过 | 0 |
实施例3 | 1.85 | 通过 | 0 |
实施例4 | 1.78 | 通过 | 0 |
实施例5 | 1.94 | 通过 | 0 |
对比例 | 2.02 | 通过 | 0 |
表中:
1.水蒸气透过率测试:
使用Mocon Permatron-W 700设备,依据标准ATSM 1249进行测试。
2.耐候性测试:
使用Q-Sun Xe-3-H型氙灯耐候老化试验箱,依据标准ISO 4892-2进行测试。
3.涂层附着力测试
依据标准ASTM 3359进行测试。
使用百格刀划格器在涂层上切出十字格子图形,切口直至底材,这样可以得到由100个小方格组成的被测单元。
使用3M公司的PSA467胶带,使胶带长度方向与其中一个划痕平行的紧密的贴附在测试区域表面上,用力压实,然后将胶带从和涂层面为0度角的方向迅速的用力撕开,观察涂层面的变化,任何面积的涂层脱落均判定为剥离强度不合格。
从表中数据可以看出,与传统方式制造的背板对比样品相比,本发明提供的含氟聚合物薄膜完全能够满足作为光伏组件产品背板的需要。
Claims (6)
1.一种太阳能电池背板,它包括基材和含氟聚合物层,其特征是,所述含氟聚合物层各组分按重量份数计为:
含氟树脂 25~45份;
改性树脂 1.5~3份;
聚合物填料 0.5~3份;
无机填料 0.1~1份;
溶剂 50~70份;
所述改性树脂是用羧酸基、磺酸基、氮杂环丙烷基、异氰酸酯基、环氧基、胺基、羟基或活性亚甲基改性处理的聚偏氟乙烯-四氟乙烯-六氟丙烯树脂。
2.根据权利要求1所述太阳能电池背板,其特征是,所述含氟树脂是偏氟乙烯、四氟乙烯、六氟丙烯的均聚物或它们的共聚物。
3.根据权利要求1或2所述太阳能电池背板,其特征是,所述含氟聚合物层包括选自如下元素的氧化物的无机填料:钛、铝、锡或硅。
4.根据权利要求3所述太阳能电池背板,其特征是,所述溶剂是甲苯、丁酮、醋酸乙酯、醋酸丁酯中的一种或几种。
5.根据权利要求4所述太阳能电池背板,其特征是,所述含氟聚合物层的厚度为25~50μm。
6.一种制备太阳能电池背板的方法,其特征是,在基材表面上涂布如权利要求1所定义的含氟聚合物层,固化得到太阳能电池背板。
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2007101852028A CN101177514B (zh) | 2007-11-08 | 2007-11-08 | 一种太阳能电池背板及其制备方法 |
JP2010532404A JP5244192B2 (ja) | 2007-11-08 | 2008-10-20 | 太陽電池用バックシート及びその製造方法 |
PCT/CN2008/001761 WO2009062384A1 (en) | 2007-11-08 | 2008-10-20 | Back sheet for solar cell and method of manufacturing the same |
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