Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
  • C08J7/04—Coating
  • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
  • Y02B10/00—Integration of renewable energy sources in buildings
  • Y02B10/10—Photovoltaic [PV]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/50—Photovoltaic [PV] energy
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
  • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
  • Y10T428/264—Up to 3 mils
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31786—Of polyester [e.g., alkyd, etc.]

Definitions

• the invention relates to a method for producing weather-resistant laminates for the encapsulation of solar cell systems and their use for the production of photovoltaic modules.
• Photovoltaic modules are used for the generation of electrical energy from sunlight and consist of a laminate, which as a core layer, a solar cell system such. Contains silicon solar cells. This core layer is encased with encapsulating materials to provide protection against mechanical and weathering effects. These materials may consist of one or more layers, of glass and / or plastic films and / or plastic film composites.
• fluoropolymer films are made in a separate process, for example by extrusion or tape casting. However, these methods are energy and costly.
• Object of the present invention is therefore to provide a method of the type mentioned, with which weather-resistant laminates can be produced energy and cost-saving even in low layer thicknesses. Furthermore, despite the low layer thicknesses, a satisfactory weather resistance for outdoor use should be achieved.
• a method for producing weather-resistant laminates for the encapsulation of solar cell systems is proposed, which is characterized in that at least one weather-resistant plastic layer is deposited on a carrier material is applied.
• the invention further relates to the use of at least two laminates produced by the process according to the invention for producing a photovoltaic module, wherein the solar cell system is attached to one of the laminates.
• This lamination process can be conducted continuously or discontinuously.
• the encapsulation material 1, 1 shows the exemplary structure of a photovoltaic module 18 with the encapsulation material 1, 1 'produced by the method according to the invention.
• the encapsulation material 1, 1 ' consist essentially of a weather-resistant layer 2, 2' and a carrier material 4, 4 ', to which an adhesion layer 5, 5' as adhesion promoter to the sealing layer 6, 6 'for the solar cell system 7 is adjacent.
• FIG. 2 shows the exemplary structure of an encapsulation material 1, as shown in FIG. 1, in which an oxide layer 8 deposited from the vapor phase is provided to further improve the weathering properties.
• Fig. 3 shows a possible device for applying the weather-resistant layer 2,2 'of a polymer solution.
• 4 shows a possible laminating device for producing a pre-bond 17 for a photovoltaic module.
• a weather-resistant layer 2, 2 'and an adhesion layer 5, 5' are applied to the substrate 4, 4 '.
• Examples a) to d) represent possible variants for the selection of the components in the respective layers:
• Weather-resistant layer 2, 2 ' selectively soluble fluoropolymers or fluorine copolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on the support materials 4, 4';
• Adhesive layer 3, 3 ' polyurethane, polyester
• Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
• PET polyethylene terephthalate
• PEN polyethylene naphthenate
• ETFE ethylene tetrafluoroethylene copolymer
• Adhesion Layer 5 polyurethane, polyacrylate or surface-treated fluoropolymer layer; Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
• EVA ethylene vinyl acetate
• PVB polyvinyl butyral
• PMMA polymethyl methacrylate
• Weather-resistant layer 2, 2 ' selectively soluble fluoropolymers or fluoropolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on pretreated support materials 4, 4';
• Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
• PET polyethylene terephthalate
• PEN polyethylene naphthenate
• ETFE ethylene tetrafluoroethylene copolymer
• Adhesion Layer 5, 5 ' polyurethane, polyacrylate or surface-treated fluoropolymer layer;
• Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
• EVA ethylene vinyl acetate
• PVB polyvinyl butyral
• PMMA polymethyl methacrylate
• polyurethane polyester or hot melt.
• Weather-resistant layer 2, 2 ' selectively soluble / dispersible fluoropolymers or fluoropolymers, with a melting point below the laminating temperature for the direct coating on the support materials 4, 4';
• Adhesive layer polyurethane, polyester
• Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
• PET polyethylene terephthalate
• PEN polyethylene naphthenate
• ETFE ethylene tetrafluoroethylene copolymer
• Adhesion layer 5, 5 1 polyurethane, polyacrylate or surface treated fluoropolymer layer;
• Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
• EVA ethylene vinyl acetate
• PVB polyvinyl butyral
• PMMA polymethyl methacrylate
• polyurethane polyester or hot melt.
• Weather-resistant layer 2, 2 ' selectively soluble / dispersible fluoropolymers or fluoropolymers, having a melting point below the laminating temperature for the direct Stratification on a pretreated substrate 4a, 4a ';
• Support material 4a, 4a ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
• PET polyethylene terephthalate
• PEN polyethylene naphthenate
• ETFE ethylene tetrafluoroethylene copolymer
• Adhesion Layer 5, 5 ' polyurethane, polyacrylate or surface-treated fluoropolymer layer;
• Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
• EVA ethylene vinyl acetate
• PVB polyvinyl butyral
• PMMA polymethyl methacrylate
• polyurethane polyester or hot melt.
• a carrier material 4, 4 ' which is selected according to examples a) to d), is provided with a weather-resistant layer 2, 2'.
• the polymers for the preparation of the weather-resistant layer 2, 2 ' are selected according to examples a) to d). If, as in examples c) and d), a weather-resistant layer, predominantly a fluoropolymer or fluorocopolymer, is used, a film uniform in its chemical constitution is produced. If, however, chemically different polymers are used, as stated in examples a) and b), it is also possible to use polymer mixtures for the weather-resistant layer 2, 2 '.
• the polymer raw materials used are varied in their ratios such that the physical and / or chemical properties of the finished weather-resistant layer 2, 2 'can be modified or optimized as desired.
• the support material can be pretreated before coating with the weather-resistant layer 2, 2 '.
• the pretreatment can be carried out on the one hand by applying an additional adhesive and on the other hand by applying an inorganic oxide layer, preferably a silicon oxide layer, deposited from the vapor phase.
• an inorganic oxide layer preferably a silicon oxide layer, deposited from the vapor phase.
• a solvent halogen-free organic solvents are used for environmental and disposal reasons.
• the solution or dispersion may further comprise dyes.
• dyes During coating, it has also proven to be advantageous to use dispersions, since when preparing a dispersion, the solvent content can be substantially reduced.
• a fluoropolymer is dissolved at 40-100 ° C. and a stirring speed of at least 2800 rpm by means of an intensive stirrer or dissolver under reflux in 2-butanone.
• Diverse fillers or dyes, such as titanium dioxide or carbon black can be added to the solution up to a proportion of 35%, based on the fluoropolymer used, so that a dispersion is formed. This is applied to the carrier material 4, 4 ', for example a pre-treated PET film, via the application devices 11.
• the layer thickness of the weather-resistant layer 2, 2 ' is controlled, which is for example in a range of 5 to 50 microns.
• the thus coated material 4, 4 ' is then fed via the deflection rollers 9a to a dryer 12, in which the solvent used is evaporated at temperatures between 80 ° and 180 ° C. Exhaust air and temperature settings in the dryer are selected so that a bubble-free, dry coating is produced. The residual solvent content of 0.3-0.6% is used as a criterion for accurate temperature adjustment.
• the carrier material 4, 4 'provided with the layer 2, 2' is further fed to the storage roll 13 via a deflection roller 9b and wound up on this.
• the carrier material 4, 4 'provided on one side with the weather-resistant layer 2, 2' can now be coated on the still uncoated surface side with the adhesion layer 5, 5 1 .
• This is done using the system shown in Fig. 3, wherein polyurethanes and fluoropolymers are used as starting materials.
• the fluoropolymers may be chemically or physically surface treated after coating.
• the lamination process is indeed a composite of the layers
• the solar cell system 7 consisting of flexible solar cell types, is applied to the encapsulation material 1 '.
• a further encapsulating material layer 1 is removed and fed to the solar cell system 7.
• the material webs drawn off from the storage rolls 9 and 9a are each fed to a heating station 14 or 14a in which the encapsulation materials 1, 1 'are heated at least to the softening temperature of the sealing layer 6, 6'. This ensures the formation of a bond between the layers 1, 1 'on the one hand and the solar cell system 7 on the other hand in the nip of the calendering station 15.
• the pre-bond is fed to a heating station 16.
• the composite 17 for a photovoltaic module can be stored on the storage roll 9b and deducted accordingly.
• the production is economical in terms of process, since the thickness of the weather-resistant layer 2, Z 'can be reduced and thus the proportion of relatively expensive fluoropolymers can be reduced.
• the process can be carried out in-situ, which the process management much easier.
• temperature ranges which are advantageously between 80 and 180 ° C. can be set so that energy-saving process control is also made possible.
• the thickness of the weather-resistant layer 2, 2 ' can be adjusted.
• this layer thickness a number of possible uses of the photovoltaic module using the encapsulation materials produced according to the invention are possible, ranging from small-scale power systems for emergency call or mobile homes to large-scale roof and façade systems as well as large-scale systems and solar power plants.

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• Condensed Matter Physics & Semiconductors (AREA)
• Electromagnetism (AREA)
• General Physics & Mathematics (AREA)
• Engineering & Computer Science (AREA)
• Computer Hardware Design (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Power Engineering (AREA)
• Physics & Mathematics (AREA)
• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Laminated Bodies (AREA)
• Photovoltaic Devices (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)
• Coating Of Shaped Articles Made Of Macromolecular Substances (AREA)

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Citations (7)

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• 2005
  • 2005-07-21 AT AT0123005A patent/AT502234B1/de not_active IP Right Cessation
• 2006
  • 2006-07-10 ZA ZA200800306A patent/ZA200800306B/en unknown
  • 2006-07-10 US US11/989,195 patent/US20090151774A1/en not_active Abandoned
  • 2006-07-10 EA EA200800385A patent/EA012305B1/ru not_active IP Right Cessation
  • 2006-07-10 AU AU2006272417A patent/AU2006272417A1/en not_active Abandoned
  • 2006-07-10 EP EP06760782A patent/EP1904300A1/de not_active Withdrawn
  • 2006-07-10 CA CA2611594A patent/CA2611594C/en not_active Expired - Fee Related
  • 2006-07-10 WO PCT/AT2006/000295 patent/WO2007009140A1/de active Application Filing
  • 2006-07-10 JP JP2008521738A patent/JP2009502030A/ja active Pending
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  • 2006-07-10 KR KR1020077027121A patent/KR20080036001A/ko not_active Application Discontinuation
  • 2006-07-10 SG SG201005257-9A patent/SG164377A1/en unknown
  • 2006-07-10 CN CNA2006800221101A patent/CN101203379A/zh active Pending
  • 2006-07-10 MX MX2008000861A patent/MX2008000861A/es unknown
  • 2006-07-20 PE PE2006000876A patent/PE20070474A1/es not_active Application Discontinuation
  • 2006-07-21 AR ARP060103157 patent/AR057079A1/es unknown
• 2007
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• 2008
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  • 2008-02-15 CR CR9732A patent/CR9732A/es not_active Application Discontinuation
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