CN102177590A - 太阳能电池模块用密封片及含该密封片的太阳能电池模块 - Google Patents
太阳能电池模块用密封片及含该密封片的太阳能电池模块 Download PDFInfo
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Abstract
本发明的太阳能电池模块用密封片通过在透明软质膜的一面或两面的表面上形成大小互不相同的多个半球形凹部,分散密封片和太阳能电池之间的层压工艺中的压力,防止太阳能电池的破损,并且易于排出空气而抑制气泡的产生。
Description
技术领域
本发明涉及太阳能电池模块用密封片及包含该密封片的太阳能电池模块。
背景技术
太阳能电池作为将太阳能直接转化为电能的太阳能发电***的核心,可由单晶硅、多晶硅或非晶硅制造。
太阳能电池几乎不会被单独使用,一般是将几到几十个太阳能电池元件串联或并联,并且为了长时间的保护进行各种封装(packaging)来使其单元化,将编入所述封装的单元称为太阳能电池模块。
近年来由于环境或能源等问题,太阳能电池受到人们的关注并被开发。太阳能电池模块一般具有如图1所示的结构。在作为表面侧透明保护部件的玻璃基板11和作为双面保护部件的双面保护膜14之间,2张密封片12a、12b包住用于太阳能电池模块的太阳能电池13。所述太阳能电池模块通过玻璃基板11、密封片12a、太阳能电池13、密封片12b及双面保护膜14按顺序层叠,通过加热和加压交联硬化密封片12a、12b,从而结合为一体。
太阳能电池模块的密封工艺通过加热和加压使密封片完全融熔之后在上下方向施加压力并脱气来实施。这时,包含交联剂的密封片由于热量而发生交联反应,这样就制造出了太阳能电池在玻璃基板和双面保护膜之间层压的太阳能电池模块。
通常,用于太阳能电池模块的密封片使用包含交联剂的透明软质树脂,一般树脂的主要成分是乙烯-醋酸乙烯共聚物(EVA)。
但是,现有的方法中当密封片粘接到太阳能电池上时,存在因为施加的压力而导致太阳能模块分开的问题。此外,脱气不充分的状态下进行交联反应时,导致太阳能模块中产生气泡,发电效率降低或可靠性变差等问题。为了改善所述问题,日本第2000-183388号公开专利中公开了通过压花加工形成连续的凹凸面的太阳能模块用密封片,其凹凸面的深度范围为15μm至50μm。形成所述凹凸面是为了在层压工艺中提高融着性或加压粘接性,提高粘接到太阳能电池时的缓冲效果。
此外,日本第2002-185027号公开专利中公开了在保护膜表面通过压花加工形成有多个凹部和/或凸部的密封片。尤其公开了密封片形成有凸部的情况,优选其凸部的形状可以是横向直径范围为0.1mm至2mm、高度范围为膜厚度的20%至95%的半球形状,并且凸部形状的面积总和相对于膜面积而言为1%至50%。
但是,这样的密封片还不足以防止太阳能电池的破损以及抑制气泡的产生,因此还需要进一步改善的密封片。
发明内容
本发明的目的在于提供一种改善了的密封片及包含所述密封片的太阳能电池模块,所述密封片防止电池的破损并抑制气泡的产生。
根据所述目的,本发明提供一种太阳能电池模块用密封片,所述密封片的透明软质膜的一面或两面上形成有大小互不相同的多个半球形凹部。此外,本发明提供包含所述太阳能电池模块用密封片的太阳能电池模块。
根据本发明的太阳能电池模块用密封片通过在其一面或两面上形成大小互不相同的多个半球形凹部,分散密封片和太阳能电池之间的层压工艺时的压力,防止太阳能电池的破损,并且易于排出空气而抑制气泡的产生。
附图说明
下面与附图一起通过下述说明来清楚描述本发明上述的以及另外的目的和技术特征。
图1为包含现有密封片的太阳能电池模块的示意图;
图2为根据本发明一个实施例的半球形凹部的截面图;
图3为根据本发明一个实施例的半球形凹部的平面图;
图4为包含本发明的密封片的太阳能电池模块的示意图;
图5为作为比较例示出的金字塔形凹部的平面图。
符号说明
具体实施方式
下面对本发明作进一步详细描述。
如图2所示,密封片上具有的半球形凹部根据长轴长度l1及短轴长度l2的比例可以为圆形或椭圆形的形状。半球形凹部长轴的长度l1优选100μm至1500μm,尤其优选500μm至1200μm的范围;短轴长度l2优选100μm至1500μm,尤其优选500μm至1200μm的范围。所述半球形凹部优选地以短轴长度l2的0.5倍以下来进行凹陷。所述半球形凹部的直径d1优选100μm至1500μm,尤其优选500μm至1200μm的范围;半球形凹部的深度h优选50μm至750μm,尤其优选200μm至600μm的范围。密封片的厚度d优选200μm至1000μm,尤其优选300μm至800μm的范围。
此外,在本发明的一个优选实施例中,以半球形凹部的总数量为基准,所述半球形凹部中,直径d1为500μm至750μm、深度h为200μm至300μm的半球形凹部的数量占10%至50%,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占45%至60%,以及直径d1为1000μm至1200μm、深度为400μm至450μm的半球形凹部的数量占5%至30%。
此外,在本发明的另一优选实施例中,以半球形凹部的总数量为基准,所述半球形凹部中,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占30%至60%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量占40%至70%。
如图3所示,根据本发明的太阳能电池模块用密封片在透明软质膜的一面或两面上形成有大小互不相同的多个半球形凹部。此外,如图3所示,多个半球形凹部优选以随机图案排列。
如图4所示,根据本发明的太阳能电池模块优选为按玻璃基板41、密封片42a、太阳能电池43、密封片42b以及双面保护膜44的顺序层叠。密封片42a,42b层压时,将设有大小互不相同的多个半球形凹部的面压住太阳能电池43,通过半球形凹部分散压力,使施加在太阳能电池43上的压力变小,从而不对太阳能电池造成破损,而且空气可通过凹部间隙排出,可抑制气泡的产生。由此,在加热加压状态下,通过对密封片42a、42b进行交联硬化,而形成粘接成整体的太阳能电池模块。
以下,对适合做本发明的密封片材料的乙烯-醋酸乙烯共聚物(EVA)树脂组合物进行说明。
作为本发明的材料使用的EVA树脂优选熔体流动速率(melt flow rate)为0.7g/10min至50g/10min,尤其优选熔体流动速率为10g/10min至45g/10min。
本发明中使用的EVA树脂组合物中可混合交联剂,以提高耐候性。交联剂一般使用在100℃以上引发自由基的有机过氧化物,尤其是考虑到配制时的稳定性时,优选使用半衰期为10小时以上、分解温度为70℃以上的有机过氧化物。作为此类有机过氧化物,可使用例如2,5-二甲基己烷、2,5-二氢过氧化物、2,5-二甲基-2,5-二(叔丁基过氧基)己烷、3-二叔丁基过氧化物、α,α’-二(叔丁基过氧化异丙基)苯、正丁基-4,4-二(叔丁基过氧化)丁烷、2,2-二(叔丁基过氧化)丁烷、1,1-二(叔丁基过氧化)环己烷、1,1-二(叔丁基过氧化)-3,3,5-三甲基环己烷、叔丁基过氧化苯乙酮、过氧化苯甲酰等。以EVA树脂100重量份为基准,此类有机过氧化物的配制量一般可以为低于5重量份,优选为0.3至2重量份。
此外,作为太阳能电池模块用密封片,为了提高与太阳能电池的粘接力,可在EVA树脂中添加硅烷结合剂。硅烷结合剂可使用公知的γ-氯丙基三甲氧基硅烷、乙烯基三氯硅烷、乙烯基三(β-甲氧基乙氧基)硅烷、γ-甲氧基丙基三甲氧基硅烷、β-(3,4-乙氧基环己基)乙基三甲氧基硅烷、γ-巯基丙基三甲氧基硅烷等等。以EVA树脂100重量份为基准,此类硅烷结合剂的配制量一般可以为低于5重量份,优选为0.1至2重量份。
此外,为了提高EVA树脂的凝胶量和耐久性,可在EVA树脂中添加交联助剂。交联助剂可使用公知的,例如三烯丙基异氰尿酸盐、三烯丙基异氰酸盐等具有3个官能团的交联助剂,脂等具有1个官能团的交联助剂。以EVA树脂100重量份为基准,此类交联助剂的配制量一般可以为低于10重量份,优选为0.1至3重量份。
此外,为了提高EVA树脂的稳定性可添加对苯二酚、甲基乙基对苯二酚、对苯醌、甲基对苯二酚等,以EVA树脂100重量份为基准,其配制量一般可以为低于5重量份。
此外,根据需要可添加上述之外的着色剂、紫外线吸收剂、抗老化剂、防变色剂等。作为着色剂的例子有金属氧化物、金属粉等无机颜料,偶氮染料、酞花青染料、酸性或碱性色淀染料等有机颜料。作为紫外线吸收剂的例子有二-羟基-4-正辛氧基二苯甲酮、二-羟基-4-甲氧基-5-砜二苯甲酮等二苯甲酮类化合物,2-(2’-羟基-5-甲基苯基)苯并***等苯并***类化合物,水杨酸苯酯、水杨酸对叔丁基苯酯等水杨酸酯类。作为抗老化剂的例子有胺类、酚类、二苯基类化合物,例如叔丁基对甲酚、二-(2,2,6,6-四甲基-4-哌啶基)葵二酸盐等。
根据本发明的密封片可使用如前所述的EVA树脂组合物,通过T型冲模或压延工艺形成200μm至1000μm的厚度后,以期望的图案进行压花加工来制造。
利用本发明的密封片的太阳能电池模块可通过以玻璃基板、密封片、太阳能电池、密封片以及双面保护膜的顺序层叠,按一定的规则使用真空层压机(laminator)将层积物在100℃至150℃温度、4分钟至12分钟的脱气时间、0.5气压至1气压的按压压力、8分钟到45分钟的按压时间下进行加热及加压来制造。本发明的密封片由于缓冲效果良好,从而防止太阳能电池在加热及加压阶段未熔融的密封片按压太阳能电池而使太阳能电池损伤,因此可高效率地制造高品质的产品。
以下,根据下述实施例对本发明进行更详细的说明。但是,下述实施例只是用于示出本发明,而非本发明的范围受这些实施例所限定。
实施例1
将作为EVA树脂的EV150(日本三井聚合化学公司;熔体流动速率:30g/10min)100重量份、作为交联剂的Luporox101(阿克玛公司)1.5重量份、作为硅烷结合剂的Z-6030(道康宁公司)0.5重量份、作为稳定剂的UV531(氰特工业公司)0.2重量份、Tinuvin770(瑞士汽巴精化股份公司)0.2重量份以及Irganox1076(瑞士汽巴精化股份公司)0.2重量份进行混合,制造自粘表面保护用膜(EVA)树脂组合物。
使用所述自粘着性表面保护用膜(EVA)树脂组合物来进行T型冲模或压延工艺,在膜的一面形成了大小为1000×1000μm且厚度d为600μm的密封片,其具备带有随机图案的半球形凹部。
膜的一面上的半球形凹部的分布为,以半球形凹部的总数量为基准,直径d1为500μm至750μm、深度h为200μm至300μm的半球形凹部的数量为50%,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量为45%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量为5%。
之后,使半球形凹部接触太阳能电池,按低铁钢化玻璃基板、所述密封片、太阳能电池(Q6LM,Q-Cell公司)、所述密封片以及双面保护膜(Dunsolar700,邓莫尔公司)顺序层叠,在150℃的加热温度、4分钟的脱气时间、1气压的按压压力、15分钟的按压时间的条件下制造了100个太阳能电池模块样品。
实施例2
在与实施例1相同的条件下,使膜的一面上的半球形凹部的分布为,以半球形凹部的总数量为基准,直径d1为500μm至750μm、深度h为200μm至300μm的半球形凹部的数量占10%,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占60%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量占30%,制造了100个太阳能电池模块样品。
实施例3
在与实施例1相同的条件下,使膜的一面上的半球形凹部的分布为,以半球形凹部的总数量为基准,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占60%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量占40%,制造了100个太阳能电池模块样品。
实施例4
在与实施例1相同的条件下,使膜的一面上的半球形凹部的分布为,以半球形凹部的总数量为基准,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占50%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量占50%,制造了100个太阳能电池模块样品。
实施例5
在与实施例1相同的条件下,使膜的一面上的半球形凹部的分布为,以半球形凹部的总数量为基准,直径d1为750μm至1000μm、深度h为300μm至400μm的半球形凹部的数量占30%,以及直径d1为1000μm至1200μm、深度h为400μm至450μm的半球形凹部的数量占70%,制造了100个太阳能电池模块样品。
比较例1
除了使用了密封片大小为1000×1000μm、密封片的厚度d为600μm的平面密封片以外,在与实施例1相同的条件下,制造了100个太阳能电池模块样品。
比较例2
除了在密封片大小为1000×1000μm、密封片的厚度d为600μm的平面密封片上以100μm的间距形成了深度为400μm的金字塔形凹部(参见图5)以外,在与实施例1相同的条件下,制造了100个太阳能电池模块样品。
实验例
以所述实施例1至5及比较例1至2中各自制造的样品为对象,调查由气泡的产生引起的不良数量和由太阳能电池的损伤引起的不良数量,并整理在下表1中。
表1
从上述表1中可以看出,比较例2与比较例1相比,由气泡的产生引起的不良数量有所减少,但是由太阳能电池的损伤引起的不良反而增加。但是,实施例1至实施例5制造的太阳能电池模块样品与比较例1及2中制造的太阳能电池模块样品相比,完全没有由气泡的产生引起的不良及由太阳能电池的损伤引起的不良。
结合上述具体实施例对本发明进行了说明,但是在不脱离权利要求书中定义的本发明的范围的前提下,本领域的技术人员可以对本发明做出若干改进和变形。
权利要求书(按照条约第19条的修改)
1.一种太阳能电池模块用密封件薄片,其特征在于,在透明软质膜的一面或两面上形成有大小互不相同的多个半球形凹部。
2.如权利要求1所述的太阳能电池模块用密封件薄片,其特征在于,所述半球形凹部的直径(d1)为100μm至1500μm,半球形凹部的深度(h)为50μm至750μm。
3.如权利要求1所述的太阳能电池模块用密封件薄片,其特征在于,以半球形凹部的总数量为基准,所述半球形凹部中,直径(d1)为500μm至750μm、深度(h)为200μm至300μm的半球形凹部的数量占10%至50%,直径(d1)为750μmμm至1000μm、深度(h)为300μm至400μm的半球形凹部的数量占45%至60%,以及直径(d1)为1000μm至1200μm、深度(h)为400μm至450μm的半球形凹部的数量占5%至30%。
4.如权利要求1所述的太阳能电池模块用密封件薄片,其特征在于,以半球形凹部的总数量为基准,所述半球形凹部中,直径(d1)为750μmμm至1000μm、深度(h)为300μm至400μm的半球形凹部的数量占30%至60%,以及直径(d1)为1000μm至1200μm、深度(h)为400μm至450μm的半球形凹部的数量占40%至70%。
5.如权利要求1所述的太阳能电池模块用密封件薄片,其特征在于,所述透明软质膜的厚度为200μm至1000μm。
6.如权利要求1所述的太阳能电池模块用密封件薄片,其特征在于,所述半球形凹部以随机(random)图案排列。
7.包含根据权利要求1到权利要求6的任一项的太阳能电池模块用密封件薄片的太阳能电池模块。
Claims (7)
1.一种太阳能电池模块用密封片,其特征在于,在透明软质膜的一面或两面上形成有大小互不相同的多个半球形凹部。
2.一种太阳能电池模块用密封片,其特征在于,半球形凹部的直径(d1)为100μm至1500μm,半球形凹部的深度(h)为50μm至750μm。
3.如权利要求1所述的太阳能电池模块用密封片,其特征在于,以半球形凹部的总数量为基准,所述半球形凹部中,直径(d1)为500μm至750μm、深度(h)为200μm至300μm的半球形凹部的数量占10%至50%,直径(d1)为750μmμm至1000μm、深度(h)为300μm至400μm的半球形凹部的数量占45%至60%,以及直径(d1)为1000μm至1200μm、深度(h)为400μm至450μm的半球形凹部的数量占5%至30%。
4.如权利要求1所述的太阳能电池模块用密封片,其特征在于,以半球形凹部的总数量为基准,所述半球形凹部中,直径(d1)为750μmμm至1000μm、深度(h)为300μm至400μm的半球形凹部的数量占30%至60%,以及直径(d1)为1000μm至1200μm、深度(h)为400μm至450μm的半球形凹部的数量占40%至70%。
5.如权利要求1所述的太阳能电池模块用密封片,其特征在于,所述透明软质膜的厚度为200μm至1000μm。
6.如权利要求1所述的太阳能电池模块用密封片,其特征在于,所述半球形凹部以随机(random)图案排列。
7.包含根据权利要求1到权利要求6的任一项的太阳能电池模块用密封片的太阳能电池模块。
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Also Published As
Publication number | Publication date |
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JP5090570B2 (ja) | 2012-12-05 |
WO2010064821A4 (ko) | 2010-10-21 |
KR20100062606A (ko) | 2010-06-10 |
KR100984136B1 (ko) | 2010-09-28 |
EP2355169A4 (en) | 2012-02-29 |
US20110203642A1 (en) | 2011-08-25 |
JP2012506159A (ja) | 2012-03-08 |
US8263854B2 (en) | 2012-09-11 |
CN102177590B (zh) | 2013-05-01 |
WO2010064821A3 (ko) | 2010-08-26 |
WO2010064821A2 (ko) | 2010-06-10 |
EP2355169A2 (en) | 2011-08-10 |
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