CN106626645A - 一种聚酯薄膜、及太阳能电池背板及其制备方法 - Google Patents
一种聚酯薄膜、及太阳能电池背板及其制备方法 Download PDFInfo
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- CN106626645A CN106626645A CN201510717263.9A CN201510717263A CN106626645A CN 106626645 A CN106626645 A CN 106626645A CN 201510717263 A CN201510717263 A CN 201510717263A CN 106626645 A CN106626645 A CN 106626645A
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- Prior art keywords
- solar cell
- polyester film
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- main stor
- thickness
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Classifications
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- 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
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Abstract
本发明涉及太阳能电池背板领域,具体涉及一种聚酯薄膜、及太阳能电池背板及其制备方法。为了解决现有太阳能电池背板不能同时具有高反射率、制备工艺简单、与EVA胶层有良好的粘结性的问题,本发明提供一种聚酯薄膜、及太阳能电池背板及其制备方法。所述聚酯薄膜包括主层和设置在主层两侧的支撑层;所述主层包括热塑性聚酯75‑85%和无机粒子15‑25%,所述无机粒子分散在热塑性聚酯中;所述支撑层包括热塑性聚酯90‑98%和耐水解性添加剂2‑10%。该太阳能电池背板具有高的反射率,能有效利用透过太阳能电池片及电池片间隙的光线,有效提高太阳能电池片的发电效率。
Description
技术领域
本发明涉及太阳能电池背板领域,具体涉及一种聚酯薄膜、及太阳能电池背板及其制备方法。
背景技术
近年来,随着化石燃料(也称矿石燃料)的日益枯竭和环境问题的加剧,光伏发电因为其清洁、可再生等优点受到越来越多的关注。太阳能电池组件是由玻璃表层、EVA胶膜、硅电池片、EVA胶膜、背板五大部分层压而成。其中,背板作为整个太阳能电池组件的支撑体,要求其具有电气绝缘性、阻水汽渗透性、耐候性、较高的机械强度,同时与封装胶膜之间有很好的粘接性能。目前,太阳能电池面临的最大问题是发电效率普遍偏低,实际使用的太阳能发电效率只能达到17%,如何提高发电效率是整个太阳能行业都必须重视的问题。太阳光透过表面玻璃到达电池片,电池片利用光能发电,若能够提高背板的反射率,有利于透过电池片及电池片间隙的光线得到反射而被重新利用,从而提高发电效率。此外,提高背板材料的反射率后,可以提高背板对紫外线的抵抗能力,缓解背板发黄和变脆的过程,有效降低背板的老化速度。
为了提高太阳能电池背板的反射率,方法之一是增加额外的反射层,如在背板的功能层中添加反射物质,如中国专利201210397317.4(公布日为2013年4月3日)在耐水解层中添加无机粒子,从而具有高反射率,背板结构为高反射率耐水解层/阻隔层/基材/阻隔层/耐水解层,各层之间通过粘接层粘接。背板的反射率在98%以上,但是此背板结构为5层,各层都通过胶粘剂粘接,生产周期较长,成本较高。中国专利201510136797.2(公布日为2015年8月12日)在基材上设置一层75-175μm的反射层。反射层是由氧化钛微粒填充的聚碳酸脂合金树脂组成,其背板的反射率也较高,但是该背板的耐候性较差,容易黄变使背板变脆,且反射层中使用氧化钛颗粒以及包含孔隙结构,在与EVA胶膜进行层压贴合时易发生分层的风险。
发明内容
为了解决现有太阳能电池背板不能同时具有高反射率、制备工艺简单、与EVA胶层有良好的粘结性的问题,本发明提供一种聚酯薄膜、及太阳能电池背板及其制备方法。该聚酯薄膜具有高的反射率。该太阳能电池背板具有高的反射率,能够提高透过电池片及电池片间隙的光线反射率,能有效利用透过太阳能电池片及电池片间隙的光线,有效提高太阳能电池片的发电效率。该太阳能电池背板与EVA胶层有良好的粘结性,且制备工艺简单。
为了解决上述技术问题,本发明采用下述技术方案:
本发明提供一种聚酯薄膜,所述聚酯薄膜包括主层和设置在主层两侧的支撑层;所述主层包括热塑性聚酯75-85%和无机粒子15-25%,所述无机粒子分散在热塑性聚酯中;所述支撑层包括热塑性聚酯90-98%和耐水解性添加剂2-10%,所述百分数是质量百分含量;所述主层的厚度为210-240μm,所述支撑层的厚度为5-25μm。
所述支撑层包括热塑性聚酯90-98%和分散在其中的耐水解性添加剂2-10%。
所述主层和支撑层是ABA三层共挤结构,所述主层是B层,所述支撑层是A层。
耐水解物质的添加量为支撑层材料的2-10%,优选为2-8%,所述百分含量为质量百分含量。若添加量低于2%,则背板的耐候性能会变差,不足以满足耐候性的要求,若添加量多于10%,则成膜性上有破膜的风险,且成本增加。
本发明还提供一种太阳能电池背板,所述背板依次包括涂覆层、聚酯薄膜层、粘接层和阻隔层;所述涂覆层涂布于聚酯薄膜层的一个表面上,所述聚酯薄膜层的另一个表面通过粘接层与阻隔层粘接在一起;所述聚酯薄膜层是本发明所述的聚酯薄膜。
进一步的,所述热塑性聚酯选自聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚萘二甲酸乙二醇酯、聚己内酰胺或聚己二酰己二胺中的一种或至少两种的组合物。
进一步的,所述无机粒子选自二氧化钛粒子、硫酸钡粒子、氧化锌粒子、碳酸钙粒子、二氧化硅粒子中的一种或至少两种的组合,所述无机粒子的粒径为0.1-1μm。
进一步的,所述耐水性添加剂选自碳化二亚胺、聚碳化二亚胺、环氧基化聚烯烃、马来酸酐化聚烯烃中的一种或至少两种的组合。
进一步的,所述粘接层的材料选自乙烯-醋酸乙烯酯、聚乙烯醇缩丁醛、环氧树脂或聚氨脂树脂中的一种或至少两种的组合物。
进一步的,所述阻隔层的材料选自聚氟乙烯树脂、聚偏氟乙烯树脂、聚四氟乙烯树脂、乙烯-四氟乙烯共聚物树脂、全氟乙烯丙烯共聚物树脂、聚三氟氯乙烯树脂、热塑性含氟树脂中的一种或至少两种的组合物;所述阻隔层的厚度为10-30μm。
进一步的,所述主层包括75-80%PET切片和20-25%TiO2粒子,TiO2粒子的平均粒径为0.2-0.4μm,支撑层包括92-98%的PET切片和2-8%的聚碳化二亚胺;所述支撑层厚度为15-20μm,主层厚度为210-220μm。
进一步的,所述主层包括80%的PET切片和20%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包括98%的PET切片和2%的聚碳化二亚胺;所述支撑层厚度为15μm,所述主层的厚度为220μm。
进一步的,所述涂覆层包括聚丙烯酸类树脂97-99%和紫外线吸收剂1-3%,所述紫外线吸收剂分散在聚丙烯酸类树脂里,所述百分数是质量百分含量;所述涂覆层的厚度为10-20μm。
进一步的,所述涂覆层包括99%的聚丙烯酸类树脂和1%的紫外线吸收剂。
进一步的,所述紫外线吸收剂选自苯并***、水杨酸苯酯、2,4-二羟基二苯甲酮、2-羟基-4-正辛氧基二苯甲酮、单苯甲酸间苯二酚酯中的一种。优选为苯并***类紫外线吸收剂。
进一步的,所述主层的热塑性聚酯为聚对苯二甲酸乙二醇酯,分散(或称填充)在其中的无机粒子优选为经过处理的二氧化钛。无机粒子的平均粒径优选为0.2-0.4μm。通过使用这一范围的平均粒径的无机粒子,可以在主层进行双向拉伸时在主层形成均匀细密的微孔,使背板具有较高的反射率。
进一步的,所述无机粒子的平均粒径为0.2μm。
进一步的,所述主层厚度为210-230μm。主层的厚度低于210μm,其反射率会偏低,若高于240μm,最终的背板会太厚而使得成本增加。
进一步的,所述支撑层厚度优选为10-20μm。
进一步的,所述支撑层中的热塑性聚酯是聚对苯二甲酸乙二醇酯,采用与主层同样的材料可以使支撑层与主层更好的相互融合,从而使太阳能电池背板在与EVA胶膜粘接后,不易发生背板主体的分层现象。
进一步的,所述支撑层中的耐水解性添加剂为聚碳化二亚胺,聚碳化二亚胺耐水解性能更好。
进一步的,在聚酯薄膜层上涂覆的是聚丙烯酸树脂。进一步的,涂覆层的厚度为15-20μm。涂覆层的作用主要是使太阳能电池背板能够更好的与EVA胶膜粘接,若太厚,与EVA的粘接性能变差,且成本较高。
进一步的,所述阻隔层的厚度为20-30μm。
进一步的,所述阻隔层的另一面涂布有白色油墨层。白色油墨层的作用是进一步提高反射率,并提高反射膜的阻隔性。白色油墨层的厚度是5-25μm,优选为5-10μm。所述阻隔层的另一面为远离粘接层的一面,也可称是阻隔层的下表面。
本发明还提供一种制备所述的太阳能电池背板的方法,所述制备方法包括如下步骤:
(1)将主层和支撑层所用的原材料按配方称量,经干燥、混料装置后分别经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却铸片,冷鼓温度为25-28℃;将厚片充分预热后,经过高拉伸比的纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层;
(2)将聚丙烯酸树脂、紫外线吸收剂按照配方配液,涂覆在聚酯薄膜层表面形成厚度为10-20μm的涂覆层;
(3)将经过涂覆的聚酯薄膜层和阻隔层通过粘接剂热压叠加复合,固化温度为80-160℃,固化时间为1-5min;收卷后在50℃-70℃下熟化24-26h,冷却后得到太阳能电池背板。
进一步的,收卷后在60℃下熟化24h,冷却后得到太阳能电池背板。
进一步的,粘接层的材料为乙烯-醋酸乙烯酯,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到太阳能电池背板。
通过上述方法得到的太阳能电池背板具有下述优势:
(1)仅复合一次阻隔膜,减少了组件的热压复合熟化时间,支撑层(也可称为耐水解层,或耐候性层)与主层基材通过三层共挤出的方式一次成型,减少复合耐水解层的工序,工艺简单,易于操作。
(2)主层热塑性聚酯中含有较高浓度的无机粒子,无机粒子在高拉伸比时与热塑性聚酯形成孔隙,使能主层结构具有很高的反射率,能够充分反射透过太阳能电池片及电池片间隙的光线,利于提高太阳能电池片的发电效率。
(3)在聚酯薄膜层表层涂覆的一层丙烯酸树脂涂覆层与传统的EVA胶水具有很好的粘接性,便于后续的操作。
与现有的高反射率太阳能电池背板相比,本发明提供的太阳能电池背板不仅具有高反射率,而且具有优异的耐候性,其耐候性层(即支撑层)与反射层(即主层)通过三层共挤出的方式一次成型,制备方法简单,易于操作;阻隔层提供良好的空气和水分的隔绝性能,更进一步的保护反射层。在背板的上层的涂覆层提供了与EVA胶膜的优异的粘接性能。
附图说明
图1为本发明提供的太阳能电池背板的剖面结构示意图
其中,1为聚酯薄膜层的主层,11为无机粒子,2为支撑层,3为涂覆层,4为粘接层,5为阻隔层。
具体实施方式
为了更易理解本发明的结构及所能达成的功能特征和优点,下文将本发明的较佳的实施例,并配合图式做详细说明如下:
如图1所示,本发明提供的太阳能电池背板依次包括涂覆层3、聚酯薄膜层、粘接层4和阻隔层5;所述涂覆层3涂布于聚酯薄膜层的一个表面上,所述聚酯薄膜层的另一个表面与阻隔层5通过粘接层4粘接在一起;所述聚酯薄膜层包括主层1和设置在主层两侧的支撑层2;所述主层1包括热塑性聚酯和无机粒子11,所述无机粒子11分散在热塑性聚酯中;所述支撑层2包括热塑性聚酯和耐水解性添加剂;所述主层的厚度为210-240μm,所述支撑层的厚度为5-25μm,所述涂覆层的厚度为10-20μm,所述阻隔层的厚度为10-30μm。
本发明提供的太阳能电池背板的主要性能测试方法如下:
1、各层的厚度:使用日本日立制作所制的S-4700型电场反射型扫描电子显微镜,以倍率500倍观察膜的剖面,以测定5点的平均值来求出反射片的各层的厚度。
2、无机粒子的平均粒径:将制膜所用的母粒原料在马弗炉中800℃煅烧后用粒度分布仪(日本堀场制作所制的LA-950型激光衍射粒度分析仪)求出粒子的粒度分布,以D50计的粒径作为平均粒径。
3、断裂伸长率保留值:按照GB/T 13542.4-2009的标准,采用美国英斯特朗公司生产的INSTRON万能材料试验机,测试太阳能电池背板的断裂伸长率,将太阳能电池背板放入型号为HT-PCT-45的PCT高压老化箱(中国东莞市华台测试仪器有限公司)进行72hr的老化试验,分别测试该太阳能电池背板在老化实验前的断裂伸长率和老化实验后的断裂伸长率,以如下公式得到此太阳能电池背板经过PCT加速老化后的断裂伸长率保留值。
断裂伸长率保留值(%)=断裂伸长率(老化实验后)/(断裂伸长率(老化实验前)×100
断裂伸长率保留值越高,说明耐候性越好。
4、水汽透过率:按照GB/T 1037-1998的标准测试,使用广州标记包装设备有限公司提供的W501型水汽透过率测定仪对太阳能背板进行测试。
5、反射率:按照GB/T 3979-2008的标准,采用美国Hunterlab公司生产的UltraScan PRO超高精度专业分光测色仪,在D65光源条件下,通过积分球d/8°结构测试其反射率,反射率数据为350nm-1050nm每隔5nm波长的光波的反射率的加权平均值,权值对应D65光源的能量分布曲线。
6、热收缩率:将聚酯薄膜层裁切为10cm×10cm的片材,使用钢尺分别测量横向和纵向尺寸S0,放置150℃烘箱内30min,拿出冷却后测试横向和纵向尺寸S1,利用公式热收缩率=(S0-S1)/S0×100分别得出聚酯薄膜层在150℃、30min的横向和纵向上的热收缩,目前要求的横向(MD)热收缩率一般为1.5%,纵向(TD)热收缩率一般为0.5%,若热收缩率过大,说明聚酯薄膜层的尺寸稳定性较差,在背板与EVA胶膜封装过程中会出现收缩带来的分层等风险。
7、聚酯薄膜层涂覆后与EVA胶膜的粘接能力:
○:粘接性能很好
△:粘接性能一般
×:粘接性能较差
实施例1
主层包括85%的PET切片和15%TiO2粒子,TiO2粒子的平均粒径为0.1μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层(也称为聚酯薄膜)。经过调节下料比例,控制支撑层厚度为10μm,主层厚度为230μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例2
主层包括85%的PET切片和15%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有95%的PET切片和5%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为15μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例3
主层包括85%的PET切片和15%TiO2粒子,TiO2粒子的平均粒径为0.4μm,支撑层包含有92%的PET切片和8%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为20μm,主层厚度为210μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例4
主层包括80%的PEN切片和20%硫酸钡粒子,硫酸钡粒子的平均粒径为0.5μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为15μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例5
主层包括75%的聚对苯二甲酸丁二醇酯切片和25%碳酸钙粒子,碳酸钙粒子的平均粒径为1μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为10μm,主层厚度为230μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例6
主层包括75%的聚己内酰胺切片和25%氧化锌粒子,氧化锌粒子的平均粒径为0.2μm,支撑层包含有95%的PET切片和5%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为15μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例7
主层包括75%的PET切片和25%TiO2粒子,TiO2粒子的平均粒径为0.4μm,支撑层包含有92%的PET切片和8%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为20μm,主层厚度为210μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例8
主层包括78%的PET切片和22%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为15μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例9
主层包括80%的PET切片和20%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为15μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例10
主层包括80%的聚己二酰己二胺切片和20%二氧化硅粒子,二氧化硅粒子的平均粒径为0.2μm,支撑层包含有98%的PET切片和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为10μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例11
主层包括80%的PET切片和20%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有90%的PET切片和10%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为10μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例12
主层包括80%的PET切片和20%硫酸钡粒子,硫酸钡粒子的平均粒径为0.2μm,支撑层包含有98%的聚对苯二甲酸丁二醇酯和2%的环氧基化聚烯烃。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为10μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2
实施例13
主层包括80%的PET切片和20%硫酸钡粒子,粒子的平均粒径为0.2μm,支撑层包含有98%的聚萘二甲酸乙二醇酯和2%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为20μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例14
主层包括80%的PET切片和20%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有95%的PET切片和5%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为20μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例15
主层包括76%的PET切片和24%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包含有96%的PET切片和4%的聚碳化二亚胺。主层和支撑层的原料按上述配方称量,经干燥、混料装置后经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却成厚片,随后厚片经过纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层。经过调节下料比例,控制支撑层厚度为20μm,主层厚度为220μm。对聚酯薄膜层各层厚度、机械性能、水汽透过率、反射率、热收缩率进行评价,评价结果总结于表1和表2。
实施例16
本发明提供的太阳能电池背板中的聚酯薄膜层,所述聚酯薄膜层包括主层和设置在主层两侧的支撑层;所述主层包括75%聚己内酰胺热塑性聚酯和25%TiO2,TiO2粒子的平均粒径为0.2μm,所述无机粒子分散在热塑性聚酯中;所述支撑层包括热塑性聚酯90%和耐水解性添加剂10%,所述百分数是质量百分含量;所述主层的厚度为220μm,所述支撑层的厚度为5μm。
实施例17
本发明提供的太阳能电池背板中的聚酯薄膜层,所述聚酯薄膜层包括主层和设置在主层两侧的支撑层;所述主层包括85%聚己内酰胺热塑性聚酯和15%二氧化硅粒子,二氧化硅粒子的平均粒径为0.2μm,所述无机粒子分散在热塑性聚酯中;所述支撑层包括热塑性聚酯95%和耐水解性添加剂5%,所述百分数是质量百分含量;所述主层的厚度为240μm,所述支撑层的厚度为25μm。
表1实施例1-17提供的技术方案的参数
表2实施例1-17提供的聚酯薄膜层的性能检测数据
由上面表2的数据可以得出,本发明提供的聚酯薄膜具有较好的耐候性、较好的水汽阻隔性、较高的反射率。特别的,实施例7,8,9,14,15提供的聚酯薄膜具有较好的断裂伸长率保留值(超过了50%)、水汽透过率(小于1.0)、反射率(高于98.10%),综合性能较好。其中,实施例9提供的聚酯薄膜的反射率最高,综合性能最好。
实施例18
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆10μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过聚乙烯醇缩丁醛与10μm厚度的聚偏氟乙烯树脂阻隔层粘接,固化温度为80℃,固化时间5min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例19
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆10μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过环氧树脂与20μm厚度的乙烯-四氟乙烯共聚物树脂阻隔层粘接,固化温度为160℃,固化时间1min。收卷后在50℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例20
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆10μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过聚氨脂树脂与30μm厚度的聚偏氟乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在70℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例21
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆15μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与10μm厚度的阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在50℃下熟化26h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例22
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆15μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与20μm厚度的聚偏氟乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化25h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例23
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆15μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与30μm厚度的聚四氟乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例24
针对如上述实施例1提供的聚酯薄膜层,在聚酯薄膜层上涂覆20μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与10μm厚度的聚四氟乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例25
针对如上述实施例7提供的聚酯薄膜层,在聚酯薄膜层上涂覆20μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与20μm厚度的聚四氟乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例26
针对如上述实施例8提供的聚酯薄膜层,在聚酯薄膜层上涂覆20μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与30μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例27
本发明提供的太阳能电池背板,在实施例14提供的聚酯薄膜层的表面上涂覆20μm厚度的涂覆层,涂覆层包括98%的聚丙烯酸树脂,2%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与20μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例28
针对如上述实施例15提供的聚酯薄膜层,在聚酯薄膜层上涂覆20μm厚度的涂覆层,涂覆层包括97%的聚丙烯酸树脂,3%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与20μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。评价结果总结于表3和表4。
实施例29
如实施例28提供的太阳能电池背板,所述阻隔层的另一面涂布有白色油墨层。白色油墨层的厚度是5μm。
实施例30
如实施例28提供的太阳能电池背板,所述阻隔层的另一面涂布有白色油墨层。白色油墨层的厚度是25μm。
实施例31
如实施例28提供的太阳能电池背板,所述阻隔层的另一面涂布有白色油墨层。白色油墨层的厚度是10μm。
实施例32
如实施例28提供的太阳能电池背板,所述阻隔层的另一面涂布有白色油墨层。白色油墨层的厚度是15μm。
对比例1
针对如上述实施例9提供的聚酯薄膜层,在聚酯薄膜层上涂覆30μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与10μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。
本对比例中涂覆层过厚,得到的反射膜与EVA胶膜的粘结性能较差,评价结果总结于表3和表4。
对比例2
针对如上述实施例14提供的聚酯薄膜层,在聚酯薄膜层上涂覆30μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与20μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。
本对比例中涂覆层过厚,得到的反射膜与EVA胶膜的粘结性能较差,评价结果总结于表3和表4。
对比例3
针对如上述实施例15供的聚酯薄膜层,在聚酯薄膜层上涂覆30μm厚度的涂覆层,涂覆层包括99%的聚丙烯酸树脂,1%的苯并***类紫外线吸收剂。得到的涂覆后的聚酯薄膜层通过乙烯-醋酸乙烯酯与30μm厚度的聚三氟氯乙烯树脂阻隔层粘接,固化温度为120℃,固化时间3min。收卷后在60℃下熟化24h,冷却后得到一体化的太阳能电池背板。
本对比例中涂覆层过厚,得到的反射膜与EVA胶膜的粘结性能较差,评价结果总结于表3和表4。
表3实施例18-32和对比例提供的技术方案的参数
表4实施例18-32和对比例提供的太阳能电池背板的性能检测数据
根据表4中的数据可以得出,本发明提供的太阳能电池背板与EVA胶膜具有优异的粘接力,良好的水汽阻隔效果与极高的反射率,能够在苛刻的条件下,有效提高太阳能电池的光线利用率,提高太阳能电池的发电效率。特别的,实施例23,25-28提供的太阳能电池背板具有较好的粘接力(评价结果均为很好“○”)、水汽透过率(小于或等于0.6)、反射率(高于98.0%),综合性能较好。其中,实施例23提供的太阳能电池背板的反射率最高,综合性能最好。
以上所述,仅为本发明的较佳实施例而已,并非用于限定本发明的保护范围。凡是根据本发明内容所做的均等变化与修饰,均涵盖在本发明的专利范围内。
Claims (10)
1.一种聚酯薄膜,其特征在于,所述聚酯薄膜包括主层和设置在主层两侧的支撑层;所述主层包括热塑性聚酯75-85%和无机粒子15-25%,所述无机粒子分散在热塑性聚酯中;所述支撑层包括热塑性聚酯90-98%和耐水解性添加剂2-10%,所述百分数是质量百分含量;所述主层的厚度为210-240μm,所述支撑层的厚度为5-25μm。
2.一种太阳能电池背板,其特征在于,所述背板依次包括涂覆层、聚酯薄膜层、粘接层和阻隔层;所述涂覆层涂布于聚酯薄膜层的一个表面上,所述聚酯薄膜层的另一个表面通过粘接层与阻隔层粘接在一起;所述聚酯薄膜层是权利要求1所述的聚酯薄膜。
3.根据权利要求2所述的太阳能电池背板,其特征在于,所述耐水性添加剂选自碳化二亚胺、聚碳化二亚胺、环氧基化聚烯烃、马来酸酐化聚烯烃中的一种或至少两种的组合。
4.根据权利要求2所述的太阳能电池背板,其特征在于,所述阻隔层的材料选自聚氟乙烯树脂、聚偏氟乙烯树脂、聚四氟乙烯树脂、乙烯-四氟乙烯共聚物树脂、全氟乙烯丙烯共聚物树脂、聚三氟氯乙烯树脂、热塑性含氟树脂中的一种或至少两种的组合物;所述阻隔层的厚度为10-30μm。
5.根据权利要求2所述的太阳能电池背板,其特征在于,所述主层包括75-80%PET切片和20-25%TiO2粒子,TiO2粒子的平均粒径为0.2-0.4μm,支撑层包括92-98%的PET切片和2-8%的聚碳化二亚胺;所述支撑层厚度为15-20μm,主层厚度为210-220μm。
6.根据权利要求2所述的太阳能电池背板,其特征在于,所述主层包括80%的PET切片和20%TiO2粒子,TiO2粒子的平均粒径为0.2μm,支撑层包括98%的PET切片和2%的聚碳化二亚胺;所述支撑层厚度为15μm,所述主层的厚度为220μm。
7.根据权利要求2所述的太阳能电池背板,其特征在于,所述涂覆层包括聚丙烯酸类树脂97-99%和紫外线吸收剂1-3%,所述紫外线吸收剂分散在聚丙烯酸类树脂里,所述百分数是质量百分含量;所述涂覆层的厚度为10-20μm。
8.根据权利7所述的太阳能电池背板,其特征在于,所述紫外线吸收剂选自苯并***、水杨酸苯酯、2,4-二羟基二苯甲酮、2-羟基-4-正辛氧基二苯甲酮、单苯甲酸间苯二酚酯中的一种。
9.根据权利2所述的太阳能电池背板,其特征在于,所述阻隔层的另一面涂布有白色油墨层。
10.一种制备权利2所述的太阳能电池背板的方法,其特征在于,所述制备方法包括如下步骤:
(1)将主层和支撑层所用的原材料按配方称量,经干燥、混料装置后分别经过双螺杆挤出机熔融混合,在模头处主层和支撑层共同挤出流延至大冷鼓上冷却铸片,冷鼓温度为25-28℃;将厚片充分预热后,经过高拉伸比的纵向拉伸、横向拉伸、定型冷却后形成聚酯薄膜层;
(2)将聚丙烯酸树脂、紫外线吸收剂按照配方配液,涂覆在聚酯薄膜层表面形成厚度为10-20μm的涂覆层;
(3)将经过涂覆的聚酯薄膜层和阻隔层通过粘接剂热压叠加复合,固化温度为80-160℃,固化时间为1-5min;收卷后在50℃-70℃下熟化24-26h,冷却后得到太阳能电池背板。
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