CN104064613A - 一种高散热型太阳能电池用一体化背板及其制造方法 - Google Patents
一种高散热型太阳能电池用一体化背板及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种高散热型太阳能电池用一体化背板，其特征在于：安装在该基材背面且通过第一导热粘接层粘接在所述基材背面的耐候阻隔层，安装在该基材正面且通过导热粘接层粘接在所述基材正面的高导热层，安装在高导热层上的保护层。通过采用上述一体化结构，可以提高组件的生产效率。由于基材背面采用上述材质且基材正面的高导热层中添加有高导热添加剂，从而提高背板的导热率，进而提高组件的发电效率。
Description
技术领域
本发明涉及一种高散热型太阳能电池用一体化背板及其制造方法，尤其涉及一种高散热型的太阳能电池用一体化背板及其制造方法，属于光伏技术领域。
背景技术
随着传统化石燃料的日趋消耗枯竭，人类不断寻求新的能源替代方案，太阳能是目前公认的绿色可再生资源，光伏(PV)发电产业自20世纪80年代以来持续高速发展，如何有效地利用太阳能成为当前新能源技术领域关注的热点，按照国家发改委编制的《可再生能源中长期发展规划》，到2020年我国光伏发电总容量要达到2500万千瓦。光伏发电系统中PV组件中，随着太阳光的不断辐照，硅电池板会随之不断升温。研究表明，硅电池温度每升高1℃，其光伏转换率会下降0.4%，也即降低了能源利用率，因此如何使硅电池板散热降温以提高光伏转换率成为当前太阳能利用领域的一大课题，然而行业内尚无成熟的解决方案。
发明内容
本发明所要解决的技术问题是提供一种高散热型太阳能电池用一体化背板及其制造方法，采用该方法制备的背板具有良好的降温效果和较好的发电效率。
为解决上述技术问题，本发明的技术方案为：一种高散热型太阳能电池用一体化背板，包括基材，其创新点在于：安装在该基材背面且通过第一导热粘接层粘接在所述基材背面的耐候阻隔层，安装在该基材正面且通过第二导热粘接层粘接在所述基材正面的高导热层，覆盖在所述高导热层上面的保护层，所述高导热层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成；所述高导热层、所述第一导热粘结层和第二导热粘结层中均添加有高导热添加剂，所述高导热添加剂由氧化锌、二氧化硅、金刚石、碳化硅、氧化铝、氮化硼、碳化硼、石墨烯、氮化铝、金属粉中的一种或多种混合而成。
优选的，所述基材由聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二酯、聚对苯二甲酸二烯丙酯、阳极氧化铝板材、聚碳酸酯中的一种或多种混合而成，且所述基材的厚度为5μm ~500μm。
优选的，所述耐候阻隔层为由聚四氟乙烯树脂、聚偏氟乙烯树脂、聚氟乙烯树脂、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、铝箔中的一种或多种混合而成，且所述耐候阻隔层的厚度为5μm ~300μm。
优选的，所述第一导热粘接层和所述第二导热粘接层均由聚氨酯胶、有机硅胶、聚合物热熔胶、环氧树脂胶中的一种或多种混合而成，所述第一导热粘接层和所述第二导热粘接层的厚度均为1μm ~50μm。
优选的，所述保护层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成，且所述保护层的厚度为10μm ~500μm。
优选的，所述高导热层厚度为15μm ~300μm。
优选的，所述高导热添加剂分别占所述高导热层、所述第一导热粘结层和所述第二导热粘结层重量比例的1%~80%。
优选的，所述高导热添加剂尺寸为0.1μm ~50μm。
一种高散热型太阳能电池用一体化背板的制造方法，用于制造上述的一种高散热型太阳能电池用一体化背板，包括以下步骤：首先将导热胶黏剂涂布在基材两侧，加热固化后形成第一导热粘结层和第二导热粘结层，通过第一导热粘接层将耐候阻隔层粘接到基材背面，接着通过第二导热粘接层将高导热层粘接到基材正面，接着在高导热层上热压复合保护层，收卷后将已经处理的基材送入烘箱熟化。
本发明的优点在于：由于高导热层和第二导热粘结层中添加有高导热添加剂，提高背板的导热率至0.5-1.5W/m·k，并使得背板具有良好的降温效果，能够降低组件的工作温度1-5℃，进而提高组件发电效率1~7.5%。另外，背板的多层结构使其具有常规背板和下层乙烯醋酸乙烯共聚物封装胶膜的双重功能，减少了组件生产时下层EVA封装胶膜的叠层步骤，提高了组件生产效率。
具体实施方式
本发明的高散热型太阳能电池用一体化背板，包括基材，安装在该基材背面且通过第一导热粘接层粘接在基材背面的耐候阻隔层，安装在该基材正面且通过第二导热粘接层粘接在基材正面的高导热层，覆盖在高导热层上面的保护层。高导热层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成，该高导热层厚度为15μm ~300μm。高导热层、第一导热粘结层和第二导热粘结层中均添加有高导热添加剂，高导热添加剂由氧化锌、二氧化硅、金刚石、碳化硅、氧化铝、氮化硼、碳化硼、石墨烯、氮化铝、金属粉中的一种或多种混合而成。另外，高导热添加剂分别占高导热层和第一导热粘结层和第二导热粘结层重量比例的1%~80%，且高导热添加剂尺寸为0.1μm ~50μm。
上述的基材由聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二酯、聚对苯二甲酸二烯丙酯、阳极氧化铝板材、聚碳酸酯中的一种或多种混合而成，且基材的厚度为5μm ~500μm。上述的耐候阻隔层为由聚四氟乙烯树脂、聚偏氟乙烯树脂、聚氟乙烯树脂、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、铝箔中的一种或多种混合而成，且耐候阻隔层的厚度为5μm ~300μm。上述的保护层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成，且保护层的厚度为10μm ~500μm。
其中，第一导热粘接层和第二导热粘接层均由聚氨酯胶、有机硅胶、聚合物热熔胶、环氧树脂胶中的一种或多种混合而成，第一导热粘接层和第二导热粘接层的厚度均为1μm ~50μm。
上述高散热型太阳能电池用一体化背板的制造方法，用于制造上述的高散热型太阳能电池用一体化背板，包括以下步骤：首先将导热胶黏剂涂布在基材两侧，加热固化后形成第一导热粘结层和第二导热粘结层，通过第一导热粘接层将耐候阻隔层粘接到基材背面，接着通过第二导热粘接层将高导热层粘接到基材正面，接着在高导热层上热压复合保护层，收卷后将已经处理的基材送入烘箱熟化。
实施例1
将导热聚氨酯胶黏剂（含有30%质量分数氧化铝）涂布在厚度为250微米的阳极氧化铝基材的两面,形成厚度为10微米的第一导热粘结层和第二导热粘结层，在80-90℃下将胶黏剂烘烤固化10分钟，然后在阳极氧化铝背面110℃下热压复合厚度为28微米的聚氟乙烯树脂形成耐候阻隔层，然后在150℃下将300微米厚度的含有10%质量分数氮化硅和20%质量分数氧化铝的聚丙烯膜热压复合在阳极氧化铝正面形成高导热层，其中氮化硅尺寸为3-5μm，氧化铝尺寸为5-10μm。接着在110℃下将厚度为150微米的乙烯醋酸乙烯共聚物胶膜热压复合在聚丙烯薄膜表面，收卷后放入烘箱中在60℃下熟化24h，冷却后得到一体化的高导热光伏背板。
该实施例所得到的一体化高导热光伏背板，导热率为0.5W/m·k，封装后的组件效率相对常规背板可分别提升1.5%。
实施例2
将导热聚氨酯胶黏剂（含有30%质量分数氧化铝）涂布在厚度为250微米的聚对苯二甲酸乙二醇酯的基材的两面,形成厚度为10微米的第一导热粘结层和第二导热粘结层，80-90℃下将胶黏剂烘烤固化10分钟，然后在聚对苯二甲酸乙二醇酯的背面120℃下热压复合厚度为28微米的聚偏氟乙烯树脂形成耐候阻隔层，然后在150℃下将300微米厚度的含有20%质量分数石墨烯的聚烯烃膜热压复合在聚对苯二甲酸乙二醇酯的正面形成高导热层，接着在110℃下将厚度为100微米的乙烯醋酸乙烯共聚物胶膜热压复合在聚烯烃薄膜表面，收卷后在60℃下熟化24h，冷却后得到一体化的高导热光伏背板。
该实施例所得到的一体化高导热光伏背板，导热率分别为1.0W/m·k，封装后的组件效率相对常规背板可分别提升3%。
实施例3
将导热聚氨酯胶黏剂（含有30%质量分数氧化铝）涂布在厚度为188微米的聚对苯二甲酸乙二醇酯的基材的两面,形成厚度为10微米的第一导热粘结层和第二导热粘结层，80-90℃下将胶黏剂烘烤固化10分钟，然后在聚对苯二甲酸乙二醇酯的背面120℃下热压复合厚度为28微米的聚氟乙烯树脂形成耐候阻隔层，然后在130℃下将300微米厚度的含有20%质量分数氮化铝和30%石墨烯的乙烯醋酸乙烯共聚物胶膜热压复合在聚对苯二甲酸乙二醇酯的正面形成高导热层，接着在110℃下将厚度为100微米的聚乙烯醇缩丁醛胶膜热压复合在高导热层表面，收卷后在60℃下熟化24h，冷却后得到一体化的高导热光伏背板。
该实施例所得到的一体化高导热光伏背板，导热率为1.5W/m·k，封装后的组件效率相对常规背板可分别提升3.5%。
以上对本发明创造的一个实施例进行了详细说明，但内容仅为本发明创造的较佳实施例，不能被认为用于限定本发明创造的实施范围。凡依本发明创造申请范围所作的均等变化与改进等，均归属于本发明创造的专利涵盖范围之内。
Claims (9)
1.一种高散热型太阳能电池用一体化背板，包括基材，其特征在于：安装在该基材背面且通过第一导热粘接层粘接在所述基材背面的耐候阻隔层，安装在该基材正面且通过第二导热粘接层粘接在所述基材正面的高导热层，覆盖在所述高导热层上面的保护层，所述高导热层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成；所述高导热层、所述第一导热粘结层和第二导热粘结层中均添加有高导热添加剂，所述高导热添加剂由氧化锌、二氧化硅、金刚石、碳化硅、氧化铝、氮化硼、碳化硼、石墨烯、氮化铝、金属粉中的一种或多种混合而成。
2.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述基材由聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二酯、聚对苯二甲酸二烯丙酯、阳极氧化铝板材、聚碳酸酯中的一种或多种混合而成，且所述基材的厚度为5μm ~500μm。
3.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述耐候阻隔层为由聚四氟乙烯树脂、聚偏氟乙烯树脂、聚氟乙烯树脂、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、铝箔中的一种或多种混合而成，且所述耐候阻隔层的厚度为5μm ~300μm。
4.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述第一导热粘接层和所述第二导热粘接层均由聚氨酯胶、有机硅胶、聚合物热熔胶、环氧树脂胶中的一种或多种混合而成，所述第一导热粘接层和所述第二导热粘接层的厚度均为1μm ~50μm。
5.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述保护层由聚烯烃、聚乙烯、聚丙烯、聚乙酸乙烯、聚氨酯树脂、乙烯醋酸乙烯共聚物、聚乙烯醇缩丁醛、环氧树脂、丙烯酸树脂、有机硅树脂中的一种或多种混合而成，且所述保护层的厚度为10μm ~500μm。
6.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述高导热层厚度为15μm ~300μm。
7.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述高导热添加剂分别占所述高导热层、所述第一导热粘结层和所述第二导热粘结层重量比例的1%~80%。
8.如权利要求1所述的一种高散热型太阳能电池用一体化背板，其特征在于：所述高导热添加剂尺寸为0.1μm ~50μm。
9.一种高散热型太阳能电池用一体化背板的制造方法，用于制造权利要求1至8中其中任意一项所述的一种高散热型太阳能电池用一体化背板，其特征在于包括以下步骤：首先将导热胶黏剂涂布在基材两侧，加热固化后形成第一导热粘结层和第二导热粘结层，通过第一导热粘接层将耐候阻隔层粘接到基材背面，接着通过第二导热粘接层将高导热层粘接到基材正面，接着在高导热层上热压复合保护层，收卷后将已经处理的基材送入烘箱熟化。
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| CN113348077A (zh) * | 2019-01-25 | 2021-09-03 | 迪睿合株式会社 | 导热性片材的制造方法 |
| CN110299425A (zh) * | 2019-06-26 | 2019-10-01 | 江苏康博光伏电力科技有限公司 | 一种快速散热的光伏背板 |
| CN110757916A (zh) * | 2019-09-25 | 2020-02-07 | 苏州中来光伏新材股份有限公司 | 一种高耐候、高水汽阻隔型太阳能电池背膜及其制备方法 |
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