TW201313848A - 用於太陽能電池模組之封裝材料及其用途 - Google Patents
用於太陽能電池模組之封裝材料及其用途 Download PDFInfo
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- TW201313848A TW201313848A TW100135800A TW100135800A TW201313848A TW 201313848 A TW201313848 A TW 201313848A TW 100135800 A TW100135800 A TW 100135800A TW 100135800 A TW100135800 A TW 100135800A TW 201313848 A TW201313848 A TW 201313848A
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- resin
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- -1 chlorotrifluoroethylene, tetrafluoroethylene, hexafluoropropylene Chemical group 0.000 claims abstract description 47
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- UUAGAQFQZIEFAH-UHFFFAOYSA-N chlorotrifluoroethylene Chemical group FC(F)=C(F)Cl UUAGAQFQZIEFAH-UHFFFAOYSA-N 0.000 claims description 10
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Classifications
-
- C—CHEMISTRY; METALLURGY
- 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
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
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Abstract
本發明提供一種用於太陽能電池模組之封裝材料,其包含一基材及至少一含氟塗層,其中該含氟塗層包含:(a)氟素樹脂,其包含由選自一氟乙烯、偏二氟乙烯、三氟氯乙烯、四氟乙烯、六氟丙烯及其組合所組成之群之氟烯烴單體所形成的均聚物或共聚物;及(b)具下式之接著促進劑:R1Si(R2)3,其中R1及R2之定義係如說明書內文所述。本發明另提供一種太陽能電池模組,其係包含上述封裝材料。
Description
本發明係關於一種用於太陽能電池模組之封裝材料及關於一種包含該封裝材料之太陽能電池模組。
由於能源短缺、溫室效應等環保問題日益嚴重,目前各國已積極研發各種可能替代能源,尤其以太陽能發電最受各界重視。
如圖1所示,一般而言,太陽能電池模組依序係由透明前板11(一般為玻璃片)、包含於密封材層12中之太陽能電池單元13及背板14所構成。
背板14的功能為保護太陽能電池模組、使其隔離環境傷害,且可提供電絕緣性及兼顧美觀功能。為了避免太陽能電池模組因接觸環境中的水、氧氣或UV光發生劣化,因此背板必須具有良好的阻水、阻氣及抗UV特性等。另,背板14需要長期、有效的與密封材層12穩固黏著,因此,也需要與密封材層12之密封材料(例如乙烯-醋酸乙烯酯(Ethylene Vinyl Acetate,EVA)共聚物)具有良好的密著性。
技術領域中常用之背板材料原為金屬基材或玻璃材料,近年來,塑膠基材(如聚酯基材),因具有重量輕且相對成本低之優勢,漸漸取代金屬基材。然而,塑膠基材易受環境影響發生降解,所以技術領域中係具備良好的阻水、阻氣及抗UV特性且在機械強度及電絕緣性方面特別優異之含氟聚合物作為塑膠基材之保護層。目前市售的具有含氟聚合物保護層的塑膠基材背板,最普遍是一種包含Tedlar/聚酯/Tedlar三層結構的層壓薄膜複合板,其具有優異的機械強度、光穩定性、耐化學性及耐候性。然而,這種多層背板在製備上需先將含氟聚合物製備成薄膜,再將其層合至塑膠基材上,因此,不但需要額外的製程設備且有製造費用昂貴的問題。
US 7,553,540揭示利用氟乙烯及偏氟乙烯之均聚物或共聚物與具有如羧酸或磺酸之官能基的黏著性聚合物摻合製得一含氟聚合物塗料,並藉由在塑膠基材併入可與該黏著性聚合物反應之官能基,以改善含氟聚合物與基材之接著力。上述方法雖可將含氟聚合物塗料塗覆在塑膠基材,取代利用含氟聚合物薄膜與基材層合之習知技術,然而,其僅適用於特定基材,或者必須先對基材進行表面處理使基材表面具有所需之官能基。
另外,具有含氟聚合物的背板,其含氟聚合物的潤濕性差,所以背板與密封材料(如EVA)貼合時往往接著力不佳。因此,在貼合前必須先於背板表面進行表面處理或在背板表面另施加一接著劑層。舉例言之,TW 201034850揭示可用一種或多種丙烯酸聚合物與一種或多種氟聚合物組成之塗層作為背板材料,其使用一底漆使背板更堅牢的黏附至EVA層。TW 201007961揭示含有三氟氯乙烯(CTFE)之三元共聚物塗層,可另添加接著劑層作為改善與EVA層間接著之用。上述先前技術由於必須使用底漆或額外的接著劑層,仍然具有製程繁瑣且製程成本較高之問題。
有鑑於此,本案發明人經廣泛研究和反覆實驗後發現一種新穎之用於太陽能電池模組之封裝材料,可有效解決前述問題。本發明之封裝材料具有特殊含氟塗層,該塗層與EVA具有優異的接著強度,故可直接與EVA貼合,並省略前處理或使用額外的接著劑層之製程,可簡化製程步驟及降低成本。此外,本發明之封裝材料與EVA密封材層間之接著性佳,因此,可避免背板因長時間暴露於環境中而與太陽能電池脫離,從而可延長太陽能電池模組之壽命。
本發明之主要目的為提供一種用於太陽能電池模組之封裝材料,該封裝材料可直接與EVA層進行熱壓合並具有優異的接著強度。
為達上述目的,本發明提供一種用於太陽能電池模組之封裝材料,其包含一基材及至少一含氟塗層,其中該含氟塗層包含:
(a)氟素樹脂,其包含由選自一氟乙烯、偏二氟乙烯、三氟氯乙烯、四氟乙烯、六氟丙烯及其組合所組成之群之氟烯烴單體所形成的均聚物或共聚物;及
(b)具下式之接著促進劑:
R1Si(R2)3
其中R1為末端具有胺基、異氰酸酯基、環氧基、乙烯基或(甲基)丙烯醯氧基的有機基團;其中各R2可相同或不相同且各自獨立選自由直鏈或分支鏈C1-4烷基、直鏈或分支鏈C1-4烷氧基及羥基所組成之群組。
本發明另提供一種包含上述封裝材料之太陽能電池模組,該太陽能電池模組包括:一透明前板、一背板、一位於該透明前板及該背板之間之密封材層、及一或複數個包含於密封材層中之太陽能電池單元,其中該透明前板或該背板中至少一者包含上述封裝材料。
本發明所用之基材可為任何本發明所屬技術領域具有通常知識者已知者,較佳係塑膠基材。上述塑膠基材並無特殊限制,係為本發明所屬技術領域中具有通常知識者所熟知者,其例如但不限於:聚酯樹脂(polyester resin),如聚對苯二甲酸乙二酯(polyethylene terephthalate,PET)或聚萘二甲酸乙二酯(polyethylene naphthalate,PEN);聚丙烯酸酯樹脂(polyacrylate resin),如聚甲基丙烯酸甲酯(polymethyl methacrylate,PMMA);聚烯烴樹脂(polyolefin resin),如聚乙烯(PE)或聚丙烯(PP);聚環烯烴樹脂(polycycloolefin resin);聚醯胺樹脂,如尼龍6、尼龍66或MXD尼龍(間二甲苯二胺/己二酸共聚物);聚醯亞胺樹脂(polyimide resin);聚碳酸酯樹脂(polycarbonate resin);聚胺基甲酸酯樹脂(polyurethane resin);聚氯乙烯(PVC);三醋酸纖維素(triacetyl cellulose,TAC);聚乳酸(polylactic acid);有取代基的烯烴類聚合物,如聚醋酸乙烯酯或聚乙烯醇;共聚物型樹脂,如EVA、乙烯/乙烯醇共聚物或乙烯/四氟乙烯共聚物;或上述之組合。較佳為聚酯樹脂、聚丙烯酸酯樹脂、聚烯烴樹脂、聚環烯烴樹脂、聚醯亞胺樹脂、聚醯胺樹脂、聚碳酸酯樹脂、聚胺基甲酸酯樹脂、聚氯乙烯、三醋酸纖維素、聚乳酸或其組合;更佳為聚對苯二甲酸乙二酯。基材之厚度並無特殊限制,通常取決於所欲製得之產品的需求,一般為約15微米(μm)至約300微米(μm)。
本發明所使用之氟素樹脂提供了耐候性佳之優點,其包含由選自一氟乙烯、偏二氟乙烯、三氟氯乙烯、四氟乙烯、六氟丙烯烯及其組合所組成之群之氟烯烴單體所形成的均聚物或共聚物,較佳由選自包含三氟氯乙烯、四氟乙烯及其組合所組成之群之氟烯烴單體所形成的共聚物,更佳係包含三氟氯乙烯之共聚物。
舉例言之,本發明所用之氟素樹脂可包含由選自三氟氯乙烯、四氟乙烯、烷基乙烯醚、烷基乙烯酯及其組合所組成之群組所形成之共聚物。根據本發明之一較佳實施態樣,本發明所用之氟素樹脂包含由三氟氯乙烯及烷基乙烯醚單體所形成之共聚物。由三氟氯乙烯與烷基乙烯醚作為聚合單元時,較易形成交替共聚物(alternative copolymer)(A-B-A-B),有利於控制所得氟素樹脂具有較高的含氟量及較佳的物化性質。根據本發明,氟烯烴單體及烷基乙烯醚單體之比例較佳係介於3:1至1:3間,更佳係介於2:1至1:2間。
本發明所用之烷基乙烯醚單體係選自由直鏈烷基乙烯醚單體、分支鏈烷基乙烯醚單體、環烷基乙烯醚單體和羥基烷基乙烯醚單體及組合所組成之群組,較佳地,該烷基乙烯醚中之烷基係具有C2至C18之碳數。
根據本發明,該氟素樹脂之含量以含氟塗層固形份總重量計為約20重量%至約95重量%,較佳為約30重量%至約85%。
以往,含氟素樹脂的封裝材料,由於氟素樹脂與密封材料(encapsulated material),例如乙烯-醋酸乙烯酯(Ethylene Vinyl Acetate,EVA),接著強度不佳,因此,封裝材料在與EVA壓合前,必須先使用底漆(primer)對封裝材料進行表面改質處理或在封裝材料表面另施加一接著劑層(adhesion layer),本案發明人發現在含氟塗層中添加特定之接著促進劑,可使封裝材料之含氟塗層與太陽能模組之密封材料產生具有大於40牛頓/厘米(40N/cm≒4kgf/cm)的剝離強度(peeling strength),能改善傳統氟素樹脂與EVA層間接著力不佳之缺點,因此可有效簡化製程。
本發明所用之接著促進劑具有下式:
R1Si(R2)3
其中R1為末端具有胺基(amino)、異氰酸酯基(isocyanate group)、環氧基(epoxy group)、乙烯基(vinyl)或(甲基)丙烯醯氧基((meth)acryloxy)的有機基團,各R2可相同或不相同且各自獨立選自由直鏈或分支鏈、C1-4烷基及直鏈或分支鏈C1-4烷氧基及羥基所組成之群組。
較佳的,R1係選自由下列基團所組成之群組:
其中R為共價鍵、直鏈或分支鏈C1-4伸烷基、或視需要經1至3個獨立選自直鏈或分支鏈C1-4烷基之取代基取代之伸苯基。
R2較佳係各自獨立選自由甲氧基、乙氧基、丙氧基、甲基、乙基及丙基所組成之群組。
上述接著促進劑之具體實施態樣,例如但不限於:
較佳係。
可用於本發明之市售接著促進劑包括但不限於:由崇越公司生產,商品名為KBE-903、KBM-1003、KBM-1403、KBM-403、KBE-9007或KBM-503者。
根據本發明,接著促進劑之含量以含氟塗層固形份總重量計為約0.5重量%至約15重量%,較佳為約1重量%至約9重量%。若接著促進劑之含量小於0.5重量%,則無法有效提升接著力;若接著促進劑之含量大於15%,則含氟塗料不安定,易影響固化後塗層的壽命。
本發明之含氟塗層可視需要包含任何本發明所屬技術領域具有通常知識者所習知之添加劑,其例如但不限於色料、填充劑、硬化劑、硬化劑促進劑、紫外線吸收劑、抗靜電劑、消光劑、安定劑、散熱助劑或防浮色劑等。
在含氟塗層中添加色料具有提升封裝材料美觀、將光反射而提高光利用效率等功效。適用於本發明之色料為顏料,其種類係為本發明所屬技術領域中具有通常知識者所熟知者,例如但不限於二氧化鈦、碳酸鈣、碳黑、氧化鐵、鉻系顏料、黑鈦等。較佳為二氧化鈦。
根據本發明之一實施態樣,本發明之含氟塗層可進一步包含一硬化劑(Curing Agent),其作用為能與氟素樹脂產生分子與分子間的化學結合,形成交聯(Crosslinking)。適用於本發之硬化劑係本發明所屬技術領域具有通常知識者所熟知者,其例如但不限於聚異氰酸酯(Polyisoc yanate)。
本發明之封裝材料包含一基材且該基材至少一側包含一含氟塗層。根據本發明之一實施態樣,該基材之一側具有一該含氟塗層。根據本發明之另一實施態樣,該基材之兩側分別具有一該含氟塗層。
本發明之封裝材料可使用任何本發明所屬技術領域中具有通常知識者所熟知之方法將含氟塗層施加至基材上而製得,例如,可將適當之塗料塗佈於基材上,進行乾燥以形成該含氟塗層。上述塗佈方法例如但不限於刮刀式塗佈(knife coating)、滾輪塗佈(roller coating)、微凹版印刷塗佈(micro gravure coating)、流塗(flow coating)、含浸塗佈(dip coating)、噴霧塗佈(spray coating)縫式塗佈法(slot die coating)、旋轉塗佈法(spin coating)、簾塗(curtain coating)、或其它習知方法、或上述方法之組合。
舉例言之,可藉由下列步驟製備根據本發明之一實施態樣之封裝材料:
(a)將氟素樹脂、接著促進劑及視需要之添加劑,於溶劑存在下混合以形成一塗料;
(b)將步驟(a)所得之塗料塗佈於基材上,並加熱乾燥;及
(c)隨後進行熟成,形成一含氟塗層。
上述步驟(a)之溶劑並無特殊限制,可為任何本發明所屬技術領域中具有通常知識者所已知的適當有機溶劑,其例如但不限於烷烴類、芳烴類、酮類、酯類、醚醇類或其混合物。
在塗料中添加有機溶劑可調整塗料黏度在適合操作的範圍。有機溶劑之含量並無特殊限制,可依實際之條件及需求而進行調整,使塗料具備所需之黏度即可。根據本發明之一實施態樣,可添加適量之溶劑,控制塗料固形份(solid content)在約10重量%至約70重量%之範圍以利操作。
適用於本發明之烷烴類溶劑例如但不限於:正己烷、正庚烷、異庚烷或其混合物。
適用於本發明之芳族烴類溶劑例如但不限於:苯、甲苯、二甲苯或其混合物。
適用於本發明之酮類溶劑例如但不限於:甲基乙基酮(MEK)、丙酮、甲基異丁基酮、環己酮、4-羥基-4-甲基-2-戊酮或其混合物。
適用於本發明之酯類溶劑例如但不限於:乙酸異丁酯(IBAC)、乙酸乙酯(EAC)、乙酸丁酯(BAC)、甲酸乙酯、乙酸甲酯、乙酸乙氧基乙酯、乙酸乙氧基丙酯、異丁酸乙酯、單甲基醚丙二醇乙酸酯、乙酸戊酯或其混合物。
適用於本發明的醚醇類溶劑例如但不限於:乙二醇丁醚(BCS)、乙二醇***乙酸酯(CAC)、乙二醇***(ECS)、丙二醇甲醚、丙二醇甲醚乙酸酯(PMA)、丙二醇單甲醚丙酸酯(PMP)、丁二醇甲醚(DBE)或其混合物。
上述步驟(b)加熱所需溫度及時間並無特殊限制,係以移除溶劑為主要目的,例如可使用80℃至180℃之溫度歷時30秒至10分鐘進行加熱。上述步驟(c)之熟成時間並無特殊限制,例如可為約1至3天。
上述所得塗層厚度並無特殊限制,其單層厚度較佳係介於1至50微米,較佳為5至30微米。
本發明之封裝材料可將塗料直接塗佈於基材並經乾燥、熟成等步驟後製得。因此,相較於必須先製備氟素樹脂薄膜再將其與基材貼合之先前技術而言,本發明之封裝材料具有製程便利且成本較低之優勢。
本發明另外提供一種太陽能電池模組,其包括如前所述之封裝材料。上述之太陽能電池模組例如但不限於矽晶太陽能電池模組(crystalline silicon solar cell)或薄膜太陽能電池模組(thin film solar cell)。上述太陽能電池模組之結構係所屬技術領域中具有通常知識者所熟知者。以矽晶太陽能電池模組而言,其可包括:一透明前板、一背板、一位於該透明前板及該背板之間之密封材層、以及一或複數個包含於密封材層中之太陽能電池單元。本發明之封裝材料可直接用作太陽能電池模組之前板或背板,並與密封材層進行熱壓合。
根據本發明之一實施態樣,本發明之太陽能電池模組包括:一透明前板、一背板、一位於該透明前板及該背板之間之密封材層、及一或複數個包含於密封材層中之太陽能電池單元,其中該透明前板或該背板中至少一者包含如本發明之封裝材料。
可使用任何本發明所屬技術領域中具有通常知識者所熟知之壓合方法將本發明之封裝材料與該密封材層貼合。舉例言之,可藉由真空壓合將本發明之封裝材料與該密封材層貼合,上述真空壓合條件並無特殊限制,例如,當密封材層為EVA時,可使用130℃至180℃之溫度,調整層壓機下蓋在20 pa至100 pa之真空下及上蓋在20 kpa至100 kpa之壓力下,加壓2至20分鐘,完成壓合步驟。上述之加壓步驟可於一段或多段完成。
本發明之封裝材料與EVA密封材層間具有良好的接著力,可直接與EVA密封材層進行壓合,不須對封裝材料之表面進行底漆塗佈(primer)或電暈(corona)等前處理步驟或使用額外的接著劑層。
以下實施例係用於對本發明作進一步說明,唯非用以限制本發明之範圍。任何熟悉此項技藝之人士可輕易達成之修飾及改變均包括於本案說明書揭示內容及所附申請專利範圍之範圍內。
下文所使用的縮寫定義如下:
EVA:乙烯-醋酸乙烯酯(Ethylene Vinyl Acetate)共聚物
PU:聚胺基甲酸酯(Polyurethane)
PMMA:聚甲基丙烯酸甲酯(polymethyl methacrylate)
(C2H5O)3SiC3H6S4C3H6Si(OC2H5)3
取14公克之氟素樹脂(長興公司提供之Eterflon 4101-60,固形份為60%,三氟一氯乙烯與烷基乙烯醚共聚物樹脂)加入塑膠瓶中,在高速攪拌下依序加入29.8公克之甲苯及0.44公克之接著促進劑(崇越公司提供之KBE-903,固形份為100%),最後加入2.3公克之硬化劑(拜耳公司提供之Desmodur 3390,固形份約75%,異氰酸酯類硬化劑),泡製成固形份約22.7重量%,總重約46.5公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約4.2重量%。
以RDS塗佈棒#50將塗料塗在PET膜上(南亞公司提供的CH885,膜厚250 μm,聚對苯二甲酸乙二酯),經140℃乾燥1分鐘,然後將膜片送入70℃的烤箱,熟成兩天後可得膜厚約20 μm之具有含氟塗層之封裝材料。
重覆實施例1步驟,唯將接著促進劑改為KBM-1003(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBM-1403(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBM-403(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBE-9007(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBM-503(崇越公司提供之KBM-503,固形份為100%)。
重覆實施例1步驟,唯將甲苯、接著促進劑及硬化劑之用量分別改為28.3公克、0.08公克及2.0公克,泡製成固形份約22.5重量%且總重約44.38公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約0.8重量%。
重覆實施例1步驟,唯將甲苯、接著促進劑及硬化劑之用量分別改為28.7公克、0.18公克及2.1公克,泡製成固形份約20.3重量%且總重約44.98公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約1.8重量%。
重覆實施例1步驟,唯將甲苯、接著促進劑及硬化劑之用量分別改為29.4公克、0.36公克及2.22公克,泡製成固形份約22.7重量%且總重約45.98公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約3.6重量%。
重覆實施例1步驟,唯將甲苯、接著促進劑及硬化劑之用量分別改為30.8公克、0.68公克及2.54公克,泡製成固形份約22.9重量%且總重約48.02公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約6.2重量%。
重覆實施例1步驟,唯將甲苯、接著促進劑及硬化劑之用量分別改為31.68公克、0.93公克及2.8公克,泡製成固形份約23.1重量%且總重約49.41公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約8.1重量%。
取37.66公克之氟素樹脂(長興公司提供之Eterflon 4101-60,固形成份為60%,三氟一氯乙烯與烷基乙烯醚共聚物樹脂)加入一塑膠瓶中,在高速攪拌下依序加入36.75公克之甲苯,22.6公克之二氧化鈦(杜邦公司提供之R-902,固形份為100%),以及3.2公克之接著促進劑(崇越公司提供之KBE-903,固形份為100%),最後加入6.85公克之硬化劑(Bayer公司提供之Desmodur 3390,固形份約75%,異氰酸酯類硬化劑),泡製成固形份約50%,總重約107公克塗料,其中接著促進劑之含量以塗料固形份總重量計係為約6.0重量%,二氧化鈦之含量以塗料固形份總重量計係為約42重量%。
以RDS塗抹棒#35將塗料塗佈在PET膜上(南亞公司提供的CH885膜厚250 μm,聚對苯二甲酸乙二酯),經140℃乾燥1分鐘,然後將膜片送入70℃的烤箱,熟成兩天後可得膜厚約25 μm之具有含氟塗層之封裝材料。
取14公克之氟素樹脂(長興公司提供之Eterflon 4101-60,固形份為60%,三氟一氯乙烯與烷基乙烯醚共聚物樹脂)加入塑膠瓶中,在高速攪拌下依序加入28公克之甲苯及1.9公克之硬化劑(拜耳公司提供之Desmodur 3390,固形份約75%,異氰酸酯類硬化劑),泡製成固形份約22.4%,總重約43.9公克塗料。
以RDS塗佈棒#50將塗料塗在PET膜上(南亞公司提供的CH885膜厚250 μm,聚對苯二甲酸乙二酯),經140℃乾燥1分鐘,然後將膜片送入70℃的烤箱,熟成兩天後可得膜厚約20 μm之具有含氟塗層之封裝材料。
取90公克之甲苯加入塑膠瓶中,在高速攪拌下加入10公克之PU粒子(台灣欣順公司提供之AH810L)至完全溶解後製備成10%之PU-甲苯溶液。
取14公克之氟素樹脂(長興公司提供之Eterflon 4101-60,固形份為60%,三氟一氣乙烯與烷基乙烯醚共聚物樹脂)加入另一塑膠瓶中,在高速攪拌下依序加入23.5公克之甲苯、9.2公克上述之PU-甲苯溶液,最後加入1.9公克之硬化劑(拜耳公司提供之Desmodur 3390,固形份約75%,異氰酸酯類硬化劑),泡製成固形成份約22.1%,總重約48.6公克塗料,其中PU之含量以塗料固形份總重量計係為約8.6重量%。
以RDS塗佈棒#50將塗料塗在PET膜上(南亞公司提供的CH885膜厚250 μm,聚對苯二甲酸乙二酯),經140℃乾燥1分鐘,然後將膜片送入70℃的烤箱,熟成兩天後可得膜厚約20 μm之具有含氟塗層之封裝材料。
取90公克之甲苯加入塑膠瓶中,在高速攪拌下加入10公克之EVA粒子(台聚公司提供之UE-654),至完全溶解後製備成10%之EVA-甲苯溶液。
重覆比較例2步驟,唯將PU-甲苯溶液改為上述之EVA-甲苯溶液。
取90公克之甲苯加入塑膠瓶中,在高速攪拌下加入10公克之聚酯樹脂粒子(長興公司提供之Eterkyd 5054),至完全溶解後製備成10%之聚酯樹脂-甲苯溶液。
重覆比較例2步驟,唯將PU-甲苯溶液改為上述之聚酯樹脂-甲苯溶液。
取90公克之甲苯加入塑膠瓶中,在高速攪拌下加入10公克之聚甲基丙烯酸甲酯樹脂粒子(長興公司提供之ETERAC 715H-18,分子量為180,000,Tg=118℃),至完全溶解後製備成10%之聚甲基丙烯酸甲酯樹脂-甲苯溶液。
重覆比較例2步驟,唯將PU-甲苯溶液改為上述之聚甲基丙烯酸甲酯樹脂-甲苯溶液。
重覆實施例1步驟,唯將接著促進劑改為KBM-573(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBM-803(崇越公司提供,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBM-802(崇越公司,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBE-846(崇越公司,固形份為100%)。
重覆實施例1步驟,唯將接著促進劑改為KBE-9103(崇越公司,固形份為100%)。
取37.66公克之氟素樹脂(長興公司提供之Eterflon 4101-60,固形成份為60%,三氟一氯乙烯與烷基乙烯醚共聚物樹脂)加入一塑膠瓶中,在高速攪拌下依序加入34.63公克之甲苯以及22.6公克之二氧化鈦(杜邦公司提供之R-902),最後加入5.11公克之硬化劑(拜耳公司提供之Desmodur 3390,固形份約75%,異氰酸酯類硬化劑),泡製成固形份約49%,總重約100克塗料,其中二氧化鈦之含量以塗料固形份總重量計係為約46重量%。
以RDS塗抹棒#35將塗料塗佈在PET膜上(南亞公司提供的CH885膜厚250 μm,聚對苯二甲酸乙二酯),經140℃乾燥1分鐘,然後將膜片送入70℃的烤箱,熟成兩天後可得膜厚約25 μm之具有含氟塗層之封裝材料。
取相同的兩片上述實施例或比較例所製備的封裝材料,裁成15 cm×10.5 cm大小之薄片。以長邊(15 cm)為上下方向、左右為短邊(10.5 cm)之方式,將塗層面相對之方式重疊放置,然後於其塗層上端分別貼上3.5 cm×10.5 cm之膠帶(MY1GA-19 mm×33 m,四維精密材料製),隨後取一13 cm×10.5 cm之EVA薄膜(型號:EV624-EVASKY,Bridgestone公司製)夾於上述貼有膠帶之兩封裝材料薄片中,使得兩封裝材料薄片塗層之上端因貼有膠帶不直接與EVA接觸,易於進行後續之剝離強度測試。
於層壓機(型號:SML-0808,欽陽公司)上放置上述所製得之試片,然後進行層壓製程:在加熱板上,在150℃±10℃之溫度下進行8分鐘真空脫泡處理(上蓋壓力為70 kpa,下蓋壓力為0 kpa);隨後於上蓋分三段施加壓力,第一段為20 kpa下歷時27秒,第二段為40 kpa歷時10秒,第三段為80 kpa下歷時6秒;最後在同為第三段施加之壓力80 kpa下歷時8分鐘後取出;待回至室溫後即可取出試片進行EVA剝離強度測試。
將與EVA薄膜壓合完成之試片沿長邊裁切成15 cm×1 cm之測試條,將預先貼有膠帶部分撕開,分別夾於微電腦拉力測試機(HT-9102,弘達公司,最高荷重100公斤)之兩夾具頭上,但夾具頭不夾到EVA層部分;且於兩夾具頭相距1 cm下,以上下180度對拉方式進行剝離強度測試。圖2為上述剝離強度測試方法之示意圖,其中21為實施例或比較例所製備之封裝材料,22為EVA薄膜。
依ASTM D1876標準測試方法進行測試,至兩夾具頭相距大於12 cm後停止測定,測得對應之剝離強度(peeling strength)值。測試時的拉伸速率為10 cm/min,剝離強度值為4 kgf/cm以上者為通過測試。所得結果記錄於表1至表4。
由表1可知,當不添加接著促進劑(比較例1)或添加高分子樹脂(比較例2至5)作為接著促進劑時,所得之封裝材料與EVA間剝離強度小於業界剝離強度測試標準(>4Kgf/cm),因此其無法有效改善含氟塗層與EVA層之剝離強度。反之,使用本發明之接著促進劑(實施例1)所製得之封裝材料可提升與EVA間剝離強度。結果顯示本發明之封裝材料在含氟塗層包含特定之接著促進劑之下,不需對表面進行前處理或另外再施加一接著劑層,即可直接與EVA層貼合並有效增加含氟塗層與EVA層之剝離強度。
由表2可知,僅有特定的含矽接著促進劑可改善含氟塗層與EVA層之剝離強度。實施例1至6使用末端具有-NH2、-NCO、環氧基、乙烯基、(甲基)丙烯醯氧基的矽烷偶合劑,可有效提升該剝離強度並符合業界剝離強度測試標準(>4Kgf/cm)。反之,比較例6至10所得剝離強度僅為0.3~2.9 Kgf/cm,不足以符合業界的需求。
由表3可知,使用本發明之接著促進劑可提升含氟塗層與EVA層間之剝離強度,有效增加含氟塗層與EVA層之接著性,且剝離強度隨著接著促進劑用量增加而增加。
由表4可知,在添加劑(二氧化鈦)存在下,使用本發明之接著促進劑仍可有效提升含氟塗層與EVA層間之剝離強度。
11...透明前板
12...密封材層
13...太陽能電池單元
14...背板
21...實施例或比較例之封裝材料
22...EVA薄膜
圖1為太陽能電池模組之示意圖;及
圖2為剝離強度測試方法之示意圖。
11...透明前板
12...密封材層
13...太陽能電池單元
14...背板
Claims (12)
- 一種用於太陽能電池模組之封裝材料,其包含一基材及至少一含氟塗層,其中該含氟塗層包含:(a) 氟素樹脂,其包含由選自一氟乙烯、偏二氟乙烯、三氟氯乙烯、四氟乙烯、六氟丙烯及其組合所組成之群組之氟烯烴單體所形成的均聚物或共聚物;及(b) 具下式之接著促進劑:R1Si(R2)3其中R1為末端具有胺基、異氰酸酯基、環氧基、乙烯基或(甲基)丙烯醯氧基的有機基團,R2各自獨立選自由直鏈或分支鏈C1-4烷基、直鏈或分支鏈C1-4烷氧基及羥基所組成之群組。
- 如請求項1之封裝材料,其中該氟素樹脂包含由選自三氟氯乙烯、四氟乙烯及其組合所組成之群組之氟烯烴單體所形成的均聚物或共聚物。
- 如請求項1之封裝材料,其中該氟素樹脂包含由三氟氯乙烯及烷基乙烯醚單體所形成之共聚物。
- 如請求項3之封裝材料,其中該烷基乙烯醚單體係選自由直鏈烷基乙烯醚單體、分支鏈烷基乙烯醚單體、環烷基乙烯醚單體和羥基烷基乙烯醚單體及其組合所組成之群組。
- 如請求項1之封裝材料,其中該氟素樹脂之含量以含氟塗層固形份總重量計,係介於20%至95%。
- 如請求項1之封裝材料,其中該接著促進劑之含量以含氟塗層固形份總重量計,係介於0.5重量%至15重量%。
- 如請求項6之封裝材料,其中該接著促進劑之含量以含氟塗層固形份總重量計,係介於1重量%至9重量%。
- 如請求項1之封裝材料,其中該基材包含聚酯樹脂、聚丙烯酸酯樹脂、聚烯烴樹脂、聚環烯烴樹脂、聚醯亞胺樹脂、聚醯胺樹脂、聚碳酸酯樹脂、聚胺基甲酸酯樹脂、聚氯乙烯、三醋酸纖維素、聚乳酸或其組合。
- 如請求項1之封裝材料,其中R1為具有下式的基團:
- 如請求項1之封裝材料,其中R2各自獨立選自由甲氧基、乙氧基、丙氧基、甲基、乙基及丙基所組成之群組。
- 如請求項9之封裝材料,其中接著促進劑為:
- 一種太陽能電池模組,其包含請求項1至11中任一項之封裝材料。
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CN201210014815.6A CN102582175B (zh) | 2011-09-30 | 2012-01-17 | 用于太阳能电池模块的封装材料及其用途 |
US13/598,697 US20130081696A1 (en) | 2011-09-30 | 2012-08-30 | Packaging material for solar cell module and uses thereof |
DE201210108040 DE102012108040A1 (de) | 2011-09-30 | 2012-08-30 | Einkapselungsmaterial für Solarzellenmodule und dessen Verwendung |
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EP2824716B1 (en) * | 2013-07-09 | 2016-12-07 | Agfa-Gevaert | A backsheet for photovoltaic modules |
CN108485159A (zh) * | 2018-03-30 | 2018-09-04 | 常州回天新材料有限公司 | 一种耐高温低水透的聚烯烃薄膜原料的制备方法 |
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CN112071936A (zh) * | 2020-08-12 | 2020-12-11 | 合肥晶澳太阳能科技有限公司 | 一种光伏组件 |
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US6737169B2 (en) * | 2001-01-31 | 2004-05-18 | Jsr Corporation | Polymer composition, cured product, laminate and method for producing the cured product |
JP4205423B2 (ja) * | 2002-12-27 | 2009-01-07 | 日新製鋼株式会社 | 接着性に優れた太陽電池基材 |
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JP5127123B2 (ja) * | 2005-07-22 | 2013-01-23 | ダイキン工業株式会社 | 太陽電池のバックシート |
US7553540B2 (en) | 2005-12-30 | 2009-06-30 | E. I. Du Pont De Nemours And Company | Fluoropolymer coated films useful for photovoltaic modules |
EP2121311A4 (en) * | 2007-02-16 | 2012-10-31 | Madico Inc | REVERSE FILM FOR A PHOTOVOLTAIC ELEMENT AND METHOD FOR YOUR REPAIR |
US20080264484A1 (en) * | 2007-02-16 | 2008-10-30 | Marina Temchenko | Backing sheet for photovoltaic modules and method for repairing same |
JP5367230B2 (ja) * | 2007-03-20 | 2013-12-11 | 三洋電機株式会社 | 太陽電池モジュール |
CN101177514B (zh) * | 2007-11-08 | 2010-06-09 | 中国乐凯胶片集团公司 | 一种太阳能电池背板及其制备方法 |
US20090272436A1 (en) * | 2008-05-05 | 2009-11-05 | Osbert Hay Cheung | Non-glass photovoltaic module and methods for manufacture |
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WO2010101811A1 (en) | 2009-03-03 | 2010-09-10 | Arkema France | Acrylic photovoltaic module backsheet |
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