CN103928549A - Castable solar module and molding method - Google Patents

Abstract

The invention relates to a castable solar module with excellent weather resistance and reliable sealing performance and a molding method, including a solar chip, the solar chip is located in a hard PVC shell cavity, and the PVC paste is sealed and coated on the The hard PVC shell cavity on the solar chip is completely filled with PVC paste. Advantages: First, PVC paste is used as the forming material for solar chip mold core sealing, which not only has good UV resistance, low temperature resistance, and weather resistance, but also has a flame retardant level of V-1 to V-0; second, it can be customized according to different users. The shape of solar panels required to be molded with castable solar modules has not only fundamentally changed the technical prejudice that those skilled in the art have long believed that PVC paste cannot be used as a sealing and forming material for solar cells, but also fundamentally changed the solar energy. The technical prejudice that chips can only be distributed in a rectangular shape and cannot be distributed along with the shape.

Description

Castable solar module and molding method

technical field

The invention relates to a castable solar module having excellent weather resistance performance, reliable sealing performance and building block splicing function and a forming method thereof, belonging to the field of castable solar module manufacture.

Background technique

1. CN103189996A, titled "solar cell sealing material", which contains an ethylene-α-olefin copolymer that satisfies the following requirements a1) to a4), a1) the proportion of constituent units derived from ethylene is 80 to 90 mol%, and the source The content ratio of the constituent units of α-olefins with 3 to 20 carbon atoms is 10 to 20 mol%, a2) the MFR measured under the conditions of 190°C and 2.16 kg load in accordance with ASTM D1238 is 2 g/10 minutes or more and Less than 10g/10 minutes, a3) The density measured according to ASTM D1505 is 0.865-0.884g/cm3, a4) The Shore A hardness measured according to ASTM D2240 is 60-85.

2. CN101375409A, titled "solar cell sealing material", contains a cross-linking resin composition (A), and the cross-linking resin composition (A) uses ethylene·(meth)acrylate copolymer as a raw material polymer, Contains the raw material polymer, an organic peroxide and a cross-linking assistant, characterized in that the decomposition temperature (1-hour half-life temperature) of the organic peroxide is below 150°C, and the organic peroxide and the cross-linking assistant The total compounding amount is in the range of 0.5 to 5 parts by weight relative to 100 parts by weight of the raw material polymer, and the proportioning ratio of organic peroxide and crosslinking auxiliary agent is that organic peroxide/crosslinking auxiliary agent is calculated by weight ratio. In the range of 1/5～1/0.1.

3. CN 101138095A, the name "solar cell sealing material", is formed by laminating the heat-resistant layer (A) and the buffer layer (B), and the bending rigidity of the adhesive heat-resistant layer (A) and the buffer layer (B) The difference in modulus is at least 30MPa.

4. CN 101872795A, name "solar module packaging structure", including: backplane; glass panel. located above the back plate; a solar cell located between the back plate and the glass panel; an adhesive substance located between the back plate and the glass panel to fix and cover the solar cell; and a first optical plate, Located above the solar cell, wherein the first optical plate is disposed between the glass panel and the solar cell and is located in the adhesive substance, and the light-receiving surface of the first optical plate away from the solar cell is positive and has Concavo-convex structure, and the surface of the first optical plate facing the solar cell is back-facing, and the first optical plate has forward high transmission and back high reflection.

Contents of the invention

Design purpose: To design a castable solar module and its molding method that not only have excellent weather resistance, but also have reliable sealing performance, and have the function of building block splicing.

Design scheme: In order to achieve the above design purpose. 1. The present invention adopts PVC paste as the design of castable solar module sealing material, which is one of the technical characteristics of the present invention. The purpose of this design is: it changes the long-term opinion of those skilled in the art that PVC paste can only be used in the field of soft materials due to its good dispersion performance, such as artificial leather, vinyl toys, soft trademarks, wallpaper, paint coatings, foaming, etc. Plastic, etc., cannot be used as a technical bias for sealing and forming materials for solar cells. On the contrary, this application adopts PVC paste as the solar cell sealing and forming material, not only can the solar panel be formed into various shapes according to the user's needs, but also the formed solar cell is easy to cast, has good light transmission effect, heat resistance and impact resistance , tear resistance, and can realize a small amount of multi-variety production. More importantly, the material realizes the fully sealed and all-weather weather-resistant use of solar cells sealed outdoors for a long time. 2. It is the second technical feature of the present invention that the pouring type solar module shell adopts the design of hard PVC material. The purpose of this design is: because the molecular structure of the hard PVC material is the same as that of the PVC paste covering the solar chip, it has good affinity. When the PVC paste is heated and cured, the molecules in the PVC paste and the hard PVC shell Molecules on the cavity wall are transferred to each other to form a complete fusion whole, so that the solar silicon wafer is in a vacuum state completely isolated from the atmosphere, which not only improves the photoelectric conversion efficiency of the solar chip, prolongs the service life of the solar chip, but also fundamentally solves the problem of To prevent household hazards from gas intrusion and rain damage to solar chips.

This application adds absorbing agent for absorbing ultraviolet rays in PVC paste and hard PVC, because ultraviolet absorbing agent can absorb the ultraviolet part in sunlight or fluorescent source, and itself structure does not change, it can convert high-energy ultraviolet light energy into Thermal energy or non-destructive longer light waves are released, thereby protecting substances added with UV absorbers from ultraviolet rays. Adding UV absorbers to PVC paste can effectively prevent ultraviolet rays in the sun from damaging solar cell sealing modules, prolonging the life of solar cells. The service life of the solar battery module.

The purpose of adding antioxidants in PVC paste and hard PVC in this application is: because the plasticized PVC paste plastics are easy to age under the action of light, heat, oxygen, solvents, additives, HCl and other factors, that is, degradation or crosslinking , to deteriorate its physical and mechanical properties and shorten its service life. The addition of antioxidants to the PVC paste of this application can effectively inhibit or reduce the thermal oxidation and photooxidative reaction speed of plastic macromolecules, significantly improve the heat resistance and light resistance of plasticized PVC paste plastics, and delay the plasticized PVC paste. The degradation and aging process of plastics can improve the weather resistance of solar cell modules made of PVC paste, and prolong the service life of plasticized PVC paste plastic products.

The purpose of adding a low-temperature plasticizer to PVC paste and hard PVC in this application is: due to the good compatibility between the low-temperature plasticizer and the PVC paste resin, the plasticizing effect is good, it is not easy to segregate, it is not easy to ooze, and the low-temperature plasticizing The agent can reduce the glass transition temperature of the plasticized PVC paste plastic, making it more flexible, and can improve the cold resistance of the plasticized PVC paste plastic, so that it still has good performance in cold regions.

The purpose of adding a stabilizer to PVC paste and hard PVC in this application is: PVC paste is plasticized or used at high temperature, and HCL is easily released to form an unstable polyene structure. At the same time, HCL has self-catalysis, which will further degrade PVC. In addition, if there is oxygen or iron, aluminum, zinc, tin, copper and cadmium plasma, it will catalyze the degradation of PVC and accelerate its aging. Therefore, various undesirable phenomena will appear in plastics, such as discoloration, deformation, cracking, decreased mechanical strength, decreased insulation performance, and brittleness. In order to solve these problems, different varieties and different numbers of stabilizers must be added to PVC paste plastics.

Technical solution 1: A castable solar module, including a solar chip, the solar chip is located in a hard PVC shell cavity, PVC paste is sealed and coated on the solar chip, and the hard PVC shell cavity is completely filled with the PVC paste.

Technical solution 2: A molding method for castable solar modules, making castable solar module molding molds according to the size of solar chips required by the user, suspending the solar chips in the cavity of the hard PVC shell, and then injecting the PVC paste into the In the mold cavity of the hard PVC shell, heat for 15-30 minutes, so that the PVC paste in the mold cavity of the hard PVC shell is solidified, and the castable solar module is obtained.

Compared with the background technology, the present invention adopts PVC paste as the forming material of solar chip mold core seal, which not only has good ultraviolet resistance, low temperature resistance and weather resistance, but also has flame retardancy up to V-2 to V-0 level; It can be used to form the shape of the required solar panel according to the different needs of users, which not only fundamentally changes the technical prejudice that those skilled in the art have long thought that PVC paste cannot be used as a sealing and forming material for solar cells, but also It has fundamentally changed the technical prejudice that solar chips can only be distributed in a rectangular shape and cannot be distributed along with the shape.

Description of drawings

Fig. 1 is a schematic cross-sectional structure diagram of a castable solar module.

Detailed ways

Embodiment 1: with reference to accompanying drawing 1. A castable solar module, comprising a solar chip 1, the solar chip 1 is located in a hard PVC shell 3 cavity, PVC paste 2 is sealed and coated on the solar chip 1 and the hard PVC shell 3 cavity is completely covered by the PVC paste 2 filling. The PVC paste on the wall of the hard PVC shell cavity is melted and solidified as one. The power cord of the solar chip 1 is sealed through the power cord hole in the hard PVC case 3 and is located outside the hard PVC case 3 . The PVC paste mentioned in this application refers to the PVC paste containing plasticizer.

Embodiment 2: On the basis of Embodiment 1, the solar chip 1 is a monolithic package, that is, a monolithic solar cell (module).

Embodiment 3: On the basis of Embodiment 1, the solar chip 1 is multi-chip package, that is, the multi-chip solar chip 1 is sealed and covered by PVC paste 2 to form a solar cell (module), and the gap between the multi-chip solar chip 1 is The series-parallel connection prior art is not described here.

Embodiment 4: On the basis of Embodiment 1, the PVC paste contains an ultraviolet absorber, and the amount of the ultraviolet absorber is 0.1 to 0.8 parts of the ultraviolet absorber added to 100 parts of the PVC paste resin. Described ultraviolet absorber is ultraviolet absorber UV-531, ultraviolet absorber UV-327, ultraviolet absorber UV-326, ultraviolet absorber UV-74, ultraviolet absorber UV-9, ultraviolet absorber UV-P one or more than one combination.

Embodiment 5: On the basis of embodiment 1, the PVC paste contains an antioxidant. The amount of antioxidant added is 100 parts of PVC paste resin, adding 0.5 to 1 part of each antioxidant. The antioxidant is one or more of antioxidant 2246, antioxidant 1520, antioxidant 1098, antioxidant 1076, antioxidant 1010, antioxidant 300, antioxidant 264, and antioxidant 168 combination.

Embodiment 6: On the basis of embodiment 1, the PVC paste contains a low temperature resistance additive. The amount of low-temperature-resistant additive added is 5-20 parts of low-temperature plasticizer to 100 parts of PVC paste resin. The low temperature resistant additives are diisodecyl adipate (abbreviated as DIDA), dioctyl adipate (abbreviated as DOA), dioctyl azelate (abbreviated as DOZ), dibutyric sebacate (abbreviated as DBS) , dioctyl sebacate (abbreviated as DOS), diisooctyl sebacate (abbreviated as DIOS) or a combination of more than one.

Embodiment 7: On the basis of embodiment 1, the PVC paste contains a stabilizer. The amount of stabilizer added is 0.5 to 5 parts of each stabilizer added to 100 parts of PVC paste resin. Described stabilizer is octyl tin mercaptide, octyl tin oxide, di-n-octyl tin dilaurate, di-n-octyl tin maleate, butyl tin mercaptide, dibutyl tin maleate, dibutyl tin laurate maleate, Dibutyltin laurate maleate, dibutyltin oxide, dimethyltin oxide, epoxy soybean oil, epoxy linseed oil, phosphite.

Embodiment 8: On the basis of Embodiment 1, the PVC paste contains a flame retardant plasticizer. The amount of flame retardant plasticizer added is 5 to 15 parts of flame retardant plasticizer per 100 parts of PVC paste resin. The flame retardant plasticizer is DP-45, tricresyl phosphate (TCP), triphenyl phosphate (TPP), tributyl phosphate (TBP), trioctyl phosphate (TOP), diphenyl-octyl phosphate (DPOP) one or more than one combination.

Embodiment 9: On the basis of the above embodiments, the area of the solar chip 1 is greater than 25 square millimeters and less than 100 square centimeters.

Embodiment 10: On the basis of the above embodiments, a castable solar module molding method, making a hard PVC shell 3 according to the size of the solar chip 1 required by the user, and suspending the solar chip 1 in the cavity of the hard PVC shell 3 , and then inject the PVC paste 2 into the cavity of the hard PVC shell 3, and heat for 15-30 minutes, so that the PVC paste 2 in the cavity of the hard PVC shell 3 is cured to obtain a castable solar module. The heating is oven heating or oven heating.

It should be understood that: although the above-mentioned embodiments have made more detailed text descriptions to the design ideas of the present invention, these text descriptions are only simple text descriptions to the design ideas of the present invention, rather than limitations to the design ideas of the present invention. The combination, addition or modification of the design concept of the present invention all fall within the protection scope of the present invention.

Claims (17)

1. A castable solar module, including a solar chip (1), characterized in that: the solar chip (1) is located in a hard PVC shell cavity, and PVC paste (2) is sealed and coated on the solar chip (1) and the hard PVC shell cavity is completely filled with PVC paste. 2. The solar cell module according to claim 1, characterized in that: the solar chip (1) is monolithically packaged. 3. The solar cell module according to claim 1, characterized in that: the solar chip (1) is a multi-chip package. 4 . The castable solar module according to claim 1 , wherein the PVC paste on the wall of the hard PVC shell cavity is melted and cured as a whole. 5. The castable solar module according to claim 1, characterized in that: the power cord of the solar chip (1) is sealed through the power cord hole in the hard PVC shell (3) and is located outside the hard PVC shell (3) . 6 . The castable solar module according to claim 1 , wherein the PVC paste contains an ultraviolet absorber. 7 . 7. The pouring solar module according to claim 6, characterized in that: the ultraviolet absorber is ultraviolet absorber UV-531, ultraviolet absorber UV-327, ultraviolet absorber UV-326, ultraviolet absorber UV -74. Ultraviolet absorber UV-9, ultraviolet absorber UV-P. 8. The castable solar module according to claim 1, wherein the PVC paste contains an antioxidant. 9. The pouring solar module according to claim 8, characterized in that: the antioxidant is antioxidant 2246, antioxidant 1520, antioxidant 1098, antioxidant 1076, antioxidant 1010, antioxidant Oxygen 300, Antioxidant 264, Antioxidant 168. 10. The castable solar module according to claim 1, characterized in that: said PVC paste contains low temperature resistant additives. 11. The castable solar module according to claim 10, characterized in that: the low temperature resistant additive is diisodecyl adipate (abbreviated as DIDA), dioctyl adipate (abbreviated as DOA), azelaic Dioctyl sebacate (DOZ for short), Dibutyric sebacate (DBS for short), Dioctyl sebacate (DOS for short), Diisooctyl sebacate (DIOS for short). 12. The castable solar module according to claim 1, characterized in that: the PVC paste contains a stabilizer. 13. The castable solar module according to claim 12, characterized in that: the stabilizer is octyl tin mercaptide, octyl tin oxide, di-n-octyl tin dilaurate, di-n-octyl tin maleate, butyl tin Tin mercaptide, dibutyltin maleate, dibutyltin laurate maleate, dibutyltin laurate maleate, dibutyltin oxide, dimethyl tin oxide, epoxy soybean oil, epoxy linseed oil, phosphorous acid fat. 14. The castable solar module according to claim 1, characterized in that: the PVC paste contains a flame retardant plasticizer. 15. The castable solar module according to claim 14, characterized in that: the flame retardant plasticizer is DP-45, tricresyl phosphate (TCP), triphenyl phosphate (TPP), tributyl phosphate Phosphate (TBP), Trioctyl Phosphate (TOP), Diphenyl Monooctyl Phosphate (DPOP). 16. A molding method for castable solar modules, characterized by: making a hard PVC shell (3) according to the size of the solar chip 1 required by the user, and suspending the solar chip (1) in the cavity of the hard PVC shell (3) , and then inject the PVC paste (2) into the cavity of the hard PVC shell (3), and heat for 15-30 minutes, so that the PVC paste (2) in the cavity of the hard PVC shell (3) is solidified, and the pouring Solid solar modules. 17. The method for molding castable solar modules according to claim 16, characterized in that: said heating is oven heating or oven heating.