Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a new packaging process method, which not only does not increase new equipment and packaging process, but also reduces the cost of packaging materials and further reduces the cost of products.
The first aspect of the present invention provides a packaging adhesive film material, which comprises a packaging material 2 and a packaging material 1 surrounding the packaging material 2, wherein the packaging material 2 is fused with the edge of the packaging material 1.
According to some embodiments of the invention, the water vapor transmission rate of the encapsulating material 1 is lower than the water vapor transmission rate of the encapsulating material 2.
According to some embodiments of the invention, the packaging material 1 has a water vapor transmission rate of 0.1g/cm or less3.d。
According to some embodiments of the invention, the encapsulating material 2 has a water vapor transmission rate > 1g/cm3.d。
According to some embodiments of the invention, the encapsulating material 1 is chosen from materials having a water vapor transmission rate of 0.1g/cm or less3D a thermoplastic polymer.
According to a preferred embodiment of the invention, the encapsulating material 1 is selected from one or more of EVB ionomer and SGP plasma polymer.
According to some embodiments of the invention, the encapsulating material 2 is selected from materials having a water vapor transmission rate > 1g/cm3D a thermoplastic polymer.
According to a preferred embodiment of the present invention, the encapsulating material 2 is selected from one or more of the polyolefin elastomers POE and polyvinyl butyral PVB.
The second aspect of the present invention provides a method for preparing the packaging adhesive film material according to the first aspect, which comprises the following steps:
s1: providing a packaging material 1 having a packaging material 2 and a long strip shape;
s2: placing the packaging material 1 around a packaging material 2 for overlapping;
s3: and fusing the packaging material 1 and the packaging material 2 by heating to form the packaging adhesive film material.
According to some embodiments of the present invention, the width of the joint of the potting material 1 and the potting material 2 is 0-10 mm.
According to some embodiments of the present invention, the packaging material 2 may be cut into a desired size from any shape without limitation. Typically, the packaging material 2 is a web with a certain width and a length of 100-200m, so that the web is cut into a desired shape.
According to some embodiments of the invention, the overlapping comprises joining or partially overlapping at S2.
According to some embodiments of the invention, the heating temperature is 100-300 ℃ in S3.
According to a preferred embodiment of the present invention, the heating temperature is 150-200 ℃ in S3.
According to some embodiments of the invention, in S3, the heating is performed for a time period of 1S to 20S.
According to a preferred embodiment of the present invention, in S3, the heating time is 5S to 10S.
According to the invention, the type, heating temperature and time of the packaging material can influence the fusion effect, and the packaging adhesive film material with better effect can be obtained at the heating temperature and time within a specific range.
The third aspect of the invention provides a use of the encapsulating adhesive film material according to the first aspect or the encapsulating adhesive film material prepared by the method according to the second aspect in encapsulating a photovoltaic module.
A fourth aspect of the invention provides a photovoltaic module comprising a photovoltaic device, a front sheet, a back sheet and the encapsulant film material according to the first aspect or the encapsulant film material prepared according to the method of the second aspect.
According to some embodiments of the invention, the size of the encapsulant 2 is smaller than the photovoltaic device size minus the insulation width.
According to some embodiments of the invention, the width of the encapsulant 1 is greater than the insulating width of the photovoltaic device.
According to some embodiments of the invention, the width of the encapsulating material 1 is 5-30 mm.
According to some embodiments of the invention, the encapsulant 2 is rectangular, wherein the length and width of the encapsulant 2 are 5-30mm less than the length and width of the photovoltaic module, respectively.
According to some embodiments of the invention, the size of the encapsulant film material is larger than the size of the photovoltaic device.
A fifth aspect of the invention provides a method of encapsulating a photovoltaic module according to the fourth aspect, comprising the steps of:
A. placing the packaging adhesive film material of the first aspect or the packaging adhesive film material prepared by the method of the second aspect between a photovoltaic device and a front plate and/or a back plate to form a laminate;
B. and carrying out lamination treatment on the laminated member to obtain the photovoltaic module.
According to some embodiments of the invention, the temperature of the lamination process is 120-.
According to some embodiments of the invention, the time of the lamination process is 3-30 min.
According to some embodiments of the invention, the pressure of the lamination process is 10 to 100 kPa.
According to some embodiments of the invention, the conditions of the lamination process comprise: the temperature is 120-180 ℃; vacuumizing for 3-8min, and pressurizing for 5-15 min; the pressurizing mode is staged pressurizing, and preferably, the pressure of the first stage is 10-30KPa, the pressure of the second stage is 30-60KPa, and the pressure of the third stage is 60-100 KPa.
In the present invention, the term "insulation width" refers to the width of the cell/film layer edge and the package plate edge, which is designed to withstand a certain high voltage and has a leakage current within a safe range.
On the basis of not adding new equipment, new materials and a new packaging process, the invention reduces the initial cost input of production line equipment, reduces the problem of product yield, reduces the difficulty of the packaging process, reduces the cost of packaging materials through material combination, and further reduces the product cost.
Detailed Description
According to the invention, by adopting a packaging material 1 (such as EVB ionic polymer, SGP ionic polymer and the like) with low water vapor transmission rate but higher cost and a packaging material 2 (polyolefin POE, ethylene, vinyl acetate EVA and the like) with higher water vapor transmission rate but lower cost, the material 2 is cut into a certain size through the thermoplastic characteristics of the two materials, and the size is smaller than the size of the insulation width removed by the photovoltaic device; cutting the material 1 into strips with a certain width, wherein the width is larger than the insulation width required by the photovoltaic device; the cut material 1 is placed on the periphery of the material 2 and is abutted or overlapped, the material 1 and the material 2 are fused through a heating device to form a packaging adhesive film sheet with the size larger than that of a single or a plurality of photovoltaic devices, the packaging adhesive film sheet is placed between the photovoltaic devices and other front plates and back plates, and the photovoltaic assembly is formed through lamination. The invention not only reduces the using amount of the packaging material 1 and the packaging cost, but also meets the packaging air tightness requirement of the film assembly.
Based on the foregoing summary, in a first aspect, the present invention provides an adhesive packaging film material, which includes a packaging material 2 and a packaging material 1 surrounding the packaging material 2, wherein the packaging material 2 is fused with the edge of the packaging material 1.
According to some embodiments of the invention, the water vapor transmission rate of the encapsulating material 1 is lower than the water vapor transmission rate of the encapsulating material 2.
According to some embodiments of the invention, the packaging material 1 has a water vapor transmission rate of 0.1g/cm or less3.d。
According to some embodiments of the invention, the encapsulating material 2 has a water vapor transmission rate > 1g/cm3.d。
According to some embodiments of the invention, the encapsulating material 1 is chosen from materials having a water vapor transmission rate of 0.1g/cm or less3D a thermoplastic polymer.
According to a preferred embodiment of the invention, the encapsulating material 1 is selected from one or more of EVB ionomer and SGP plasma polymer.
According to some embodiments of the invention, the encapsulating material 2 is selected from materials having a water vapor transmission rate > 1g/cm3D a thermoplastic polymer.
According to a preferred embodiment of the present invention, the encapsulating material 2 is selected from one or more of the polyolefin elastomers POE and polyvinyl butyral PVB.
In a second aspect, the present invention provides a method for preparing the packaging adhesive film material according to the first aspect, which comprises the following steps:
s1: providing a packaging material 1 having a packaging material 2 and a long strip shape;
s2: placing the packaging material 1 around a packaging material 2 for overlapping;
s3: and fusing the packaging material 1 and the packaging material 2 by heating to form the packaging adhesive film material.
According to some embodiments of the present invention, the width of the joint of the potting material 1 and the potting material 2 is 0-10 mm.
According to some embodiments of the present invention, the packaging material 2 may be cut into a desired size from any shape without limitation. Typically, the packaging material 2 is a web with a certain width and a length of 100-200m, so that the web is cut into a desired shape.
According to some embodiments of the invention, the overlapping comprises joining or partially overlapping at S2.
According to some embodiments of the invention, the heating temperature is 100-300 ℃ in S3.
According to a preferred embodiment of the present invention, the heating temperature is 150-200 ℃ in S3.
According to some embodiments of the invention, in S3, the heating is performed for a time period of 1S to 20S.
According to a preferred embodiment of the present invention, in S3, the heating time is 5S to 10S.
According to the invention, the type, heating temperature and time of the packaging material can influence the fusion effect, and the packaging adhesive film material with better effect can be obtained at the heating temperature and time within a specific range.
In a third aspect, the present invention provides a use of the encapsulating adhesive film material according to the first aspect or the encapsulating adhesive film material prepared by the method according to the second aspect in encapsulating a photovoltaic module.
In a fourth aspect, the present invention provides a photovoltaic module comprising a photovoltaic device, a front sheet, a back sheet and an encapsulant film material according to the first aspect or the encapsulant film material prepared according to the method of the second aspect.
According to some embodiments of the invention, the size of the encapsulant 2 is smaller than the photovoltaic device size minus the insulation width.
According to some embodiments of the invention, the width of the encapsulant 1 is greater than the insulating width of the photovoltaic device.
According to some embodiments of the invention, the width of the encapsulating material 1 is 5-30 mm.
According to some embodiments of the invention, the encapsulant 2 is rectangular, wherein the length and width of the encapsulant 2 are 5-30mm less than the length and width of the photovoltaic module, respectively.
According to some embodiments of the invention, the size of the encapsulant film material is larger than the size of the photovoltaic device.
In a fifth aspect, the present invention provides a method of encapsulating a photovoltaic module according to the fourth aspect, comprising the steps of:
A. placing the packaging adhesive film material of the first aspect or the packaging adhesive film material prepared by the method of the second aspect between a photovoltaic device and a front plate and/or a back plate to form a laminate;
B. and carrying out lamination treatment on the laminated member to obtain the photovoltaic module.
According to some embodiments of the invention, the temperature of the lamination process is 120-.
According to some embodiments of the invention, the time of the lamination process is 3-30 min.
According to some embodiments of the invention, the pressure of the lamination process is 10 to 100 kPa.
According to some embodiments of the invention, the conditions of the lamination process comprise: the temperature is 120-180 ℃; vacuumizing for 3-8min, and pressurizing for 5-15 min; the pressurizing mode is staged pressurizing, and preferably, the pressure of the first stage is 10-30KPa, the pressure of the second stage is 30-60KPa, and the pressure of the third stage is 60-100 KPa.
According to some specific embodiments of the present invention, the present invention provides a method for encapsulating a photovoltaic module, specifically, as shown in fig. 1, cutting an encapsulating material 1 into strips with a width of 5-30mm, combining the size of the encapsulating material 2 with a size of cutting a length and a width which are less than the length and the width of the photovoltaic module by 5-30mm, placing the encapsulating material 2 on a platform with a surface covered with teflon, placing the encapsulating material 1 on the periphery of the encapsulating material 2, overlapping the two materials with a width of 0-10mm, heating to about 160 ℃, covering the surface of the device with the teflon, contacting and pressing the overlapping part of the encapsulating material 1 and the encapsulating material 2 by a heating device for a certain time, adhering and melting the encapsulating material 1 and the encapsulating material 2 into a whole, placing the combined encapsulating material between the photovoltaic device and a front plate or (and) a back plate, and putting the photovoltaic module into a laminating machine, and forming the photovoltaic module through a certain laminating process.
The present invention will be more fully understood by those skilled in the art by describing the present invention in detail with reference to the following examples, which should not be construed as limiting the scope of the present invention in any way.
The starting materials or components used in the present invention may be commercially or conventionally prepared unless otherwise specified.
Example 1
Cutting an encapsulating material 1(EVB ionic polymer) into strips with the width of 15mm, cutting the size of an encapsulating material 2(POE polyolefin elastomer) into the size with the length smaller than the length of a photovoltaic device by 12mm and the width smaller than the width of the photovoltaic device by 10mm, placing the encapsulating material 2 on a platform with the surface covered with polytetrafluoroethylene, placing the encapsulating material 1 on the periphery of the encapsulating material 2, overlapping the two materials together, wherein the overlapping width of the length is 5mm and the overlapping width of the width is 3mm, heating the device to 160 ℃ to ensure that the surface of the device is covered with the polytetrafluoroethylene, contacting and pressing the overlapping part of the encapsulating material 1 and the encapsulating material 2 by a heating device for 1-20s, melting and adhering the encapsulating material 1 and the encapsulating material 2 into a whole, placing the combined encapsulating material between the photovoltaic device and a front plate or (or) a back plate, placing the combined material into a laminating machine, laminating the combined material by a certain laminating, vacuumizing for 3min, pressurizing for 10min, and pressurizing for three sections of 20KPa/60KPa/100KPa) to form the photovoltaic module.
Example 2
Cutting an encapsulating material 1(EVB ionic polymer) into a strip shape with the width of 20mm, cutting the size of an encapsulating material 2(POE polyolefin elastomer) into the size with the length of 20mm less than the length of a photovoltaic device and the width of 20mm less than the width of the photovoltaic device, placing the encapsulating material 2 on a platform with the surface covered with polytetrafluoroethylene, placing the encapsulating material 1 on the periphery of the encapsulating material 2 to be in contact, overlapping the two materials together, wherein the length overlapping width is 0mm, the width overlapping width is 0mm, heating the device to 170 ℃ to ensure that the surface of the device is covered with the polytetrafluoroethylene, contacting and pressing the overlapping part of the encapsulating material 1 and the encapsulating material 2 through a heating device for 1-20s, melting and adhering the encapsulating material 1 and the encapsulating material 2 into a whole, placing the combined encapsulating material between the photovoltaic device and a front plate or (and) a back plate, placing the combined material into a laminating machine, laminating at a specific laminating temperature of, vacuumizing for 3min, pressurizing for 10min, and pressurizing for three sections of 20KPa/60KPa/100KPa) to form the photovoltaic module.
It should be noted that the above-mentioned embodiments are only for explaining the present invention, and do not set any limit to the present invention. The invention has been described with reference to an exemplary embodiment, but the words which have been used herein are words of description and illustration, rather than words of limitation. The invention can be modified, as prescribed, within the scope of the appended claims, and changes can be made thereto without departing from the spirit and scope of the invention. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein, but rather extends to all other methods and applications having the same functionality.