TWI429091B - Backsheet structure for solar plate module and its fabrication method - Google Patents

Description

Backplane structure of solar panel module and its preparation method

The invention relates to a packaging technology of a solar panel module, in particular to a backboard structure of a solar panel module and a manufacturing method thereof.

With the increasing awareness of energy saving and carbon and the increasing demand for green energy, solar power has become one of the important alternative energy sources. Generally, solar panel modules are usually installed outdoors, and the outdoor environment such as moisture and high temperature may be detrimental to the solar module. Therefore, the composition and material structure of the solar panel module are required to have sufficient durability and weather resistance, especially The back sheet is required to have weather resistance and a small water vapor transmission rate. Because when the package is peeled or discolored due to moisture penetration, the line is corroded, which will affect the output power of the module itself.

Following the above description, as shown in FIG. 1 , in the structure of a general solar panel module, the component enclosed in the package is called a solar cell module 100, and the upper layer of the solar cell module 100 is made of a thermoplastic plastic 110 (such as ethylene). A package composed of vinyl acetate copolymer resin (EVA) is packaged to fill the gap of the solar cell module 100. The surface of the solar cell module 100 that is exposed to sunlight is generally covered by the glass 120. Further, the inner surface of the solar cell module 100 is protected by a back sheet 130 made of a sheet of heat-resistant and weather-resistant plastic material. The production of the back sheet is mostly a coating and laminating process, and it takes several days to mature in the mature chamber, so that the back sheet product is warped after being cooked.

Generally, the packaging of the solar panel module adopts a lamination process, and the temperature is about 150 ° C. Usually, when the membranes are stacked with the solar cell module, multiple placement processes or warpage between the membranes are different. In turn, it affects the overlap yield.

In order to solve the above problems, one of the objects of the present invention is to provide a backplane structure of a solar panel module and a method for manufacturing the same, which integrates a sealing material layer and an electrical insulating layer into a composite backing plate by an extrusion method. No additional paint sticking is required and the ripening step is omitted and the warpage value of the product is low.

One of the objects of the present invention is to provide a back panel structure of a solar panel module and a method for fabricating the same, which can reduce the probability of fragmentation due to height difference, and has a low shrinkage rate and can reduce the probability of fragmentation and poor solar cell module wiring. The chance.

One of the objects of the present invention is to provide a back panel structure of a solar panel module and a method of manufacturing the same, which can reduce the generation of an air layer when the package is stacked, and thus can have a faster pumping and discharging rate and a better layer bonding force.

A back sheet structure of a solar panel module according to an embodiment of the present invention includes: an electrically insulating layer; and a sealing material layer directly formed on the electrically insulating layer by a hot melt extrusion method and the sealing material The surface above the layer has a surface embossed structure.

A method for fabricating a backplane structure of a solar panel module according to an embodiment of the invention includes the steps of: providing an electrically insulating layer; and forming a layer of sealing material directly on the electrically insulating layer by a hot melt extrusion method The upper surface of the upper sealing material layer has a surface embossed structure.

The purpose, technical contents, features, and effects achieved by the present invention will become more apparent from the detailed description of the appended claims.

The detailed description is as follows, and the preferred embodiment is not intended to limit the invention. 2 is a schematic view showing the structure of a back plate of a solar panel module according to an embodiment of the present invention. In this embodiment, the backplane structure of the solar panel module includes: an electrically insulating layer 200; and a sealing material layer 300. The sealing material layer 300 is directly formed on the electrically insulating layer 200 by a hot melt extrusion method. And the upper surface of the sealing material layer 300 has a surface embossed structure.

Following the above description, the material of the sealing material layer 300 is a cross-linked packaging material. For example, in one embodiment, it may be an ethylene-vinyl acetate copolymer (EVA). In addition, the material of the sealing material layer 300 may also be a polyvinyl butyral resin (PVB).

Referring to FIG. 3A, the sealing material layer 300 may be a multi-layered structure, such as two layers, which is composed of a co-molding. The material of the first sealing material layer 310 having one of the surface embossed structures is selected from the group consisting of ethylene-vinyl acetate copolymer (EVA) or polyvinyl butyral (PVB). The material of a second sealing material layer 320 stacked under the first sealing material layer 310 is selected from the group consisting of ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral resin (PVB), and vinyl polymer (Polyolefins). ), thermoplastic elastomer (TPE), such as thermoplastic elastomer (TPO), thermoplastic vulcanizate (TPV), fluorocarbon rubber, fluorocarbon rubber.

Next, please refer to FIG. 3B. In an embodiment, the sealing material layer 300 may also be a three-layer laminated structure. The material of a third sealing material layer 330 stacked under the second sealing material layer 320 is selected from the group consisting of ethylene-vinyl acetate copolymer (EVA) or polyvinyl butyral resin (PVB).

In the present invention, the electrically insulating layer 200 in the backplane structure is a weather film. In addition to electrical insulation properties, it is necessary to prevent gas and moisture from entering the solar panel module. In one embodiment, the material of the electrically insulating layer 200 is fluoroplastics. In one embodiment, the material of the electrically insulating layer 200 may be selected from the group consisting of Poly-Vinyl Fluoride (PVF), polyvinylidene fluoride (PVDF), and ethylene-tetrafluoroethylene (Ethylene-tetrafluoroethylene). ETFE), Perfluoronated ethylene propylene copolymer (EFEP), Polypropylene (PP), Polycarbonate (PC) or Nylon blended with ethylene and vinyl alcohol copolymer (Nylon) -EVOH). Wherein, in one embodiment, fluoroplastics may be selectively blended with polyolefins. In an embodiment, the electrically insulating layer 200 is selectively blendable. Nano-clay.

Moreover, in another embodiment, the material of the electrically insulating layer 200 is a thermoplastic elastomer (TPE), which may be selected from a thermoplastic elastomer (TPO), such as ethylene propylene diene monomer. (ethylene propylene diene terpolymer rubber, EPDM), ethylene propylene rubber (EPR), thermoplastic vulcanizates (TPV), fluorocarbon rubber, fluorocarbon rubber.

Next, referring to FIG. 4, in an embodiment, the electrically insulating layer 200 is a multi-layered structure, such as two layers. The multi-layered structure includes a first electrically insulating layer 210 in contact with the sealing material layer 300 (shown in FIG. 2) for use as a moisture resistant layer; and a second electrically insulating layer 220 stacked on the first electrical layer. The insulating layer 210 is under.

Following the above description, in an embodiment, the material of the first electrical insulating layer 210 may be a polyolefin. In one embodiment, the material of the first electrically insulating layer 210 may also be a thermoplastic elastomer (TPE), a thermoplastic elastomer (TPO), or a thermoplastic vulcanizate (TPV). In one embodiment, the material of the first electrically insulating layer 210 may be polyethylene terephthalate (PET) or polycarbonate (PC). . The second electrical insulating layer 220 is made of fluoroplastics and is selected from the group consisting of Poly-Vinyl Fluoride (PVF), polyvinylidene fluoride (PVDF), and ethylene-tetrafluoroethylene copolymer (Ethylene). -tetrafluoroethylene, ETFE) or a copolymer of tetrafluoroethylene and hexafluoropropylene (EFEP). Wherein, in one embodiment, fluoroplastics may be selectively blended with polyolefins.

Following the above description, in an embodiment (not shown), an organic or inorganic dye such as barium sulfate (BaSO ₄ ), calcium carbonate (CaCO ₃ ), or titanium dioxide may be selectively added to the first electrically insulating layer 210 ( TiO ₂ ) or carbon black. In another embodiment, a skin layer containing an organic or inorganic dye may be selectively disposed on the upper surface or the lower surface of the first electrically insulating layer 210, not shown. In one embodiment, fluoroplastics may also be added to the surface layer. In one embodiment, an organic or inorganic dye may also be added to the inner interlayer of the first electrically insulating layer 210, not shown. In an embodiment, a water blocking material such as polypropylene (PP), polyethylene (polyethlene, PE), and nylon (PA) may be added to the skin layer of the first electrically insulating layer 210. , ethylene-vinyl acetate copolymer (EVA), ethylene propylene diene terpolymer rubber (EPDM), ethylene propylene rubber (EPR) or copolymerization of ethylene and vinyl alcohol (ethylene vinyl alcohol, EVOH).

In one embodiment, the material of the first electrically insulating layer 210 may be a polycarbonate-polyester alloy, and an organic or inorganic dye may be selectively added to the first electrically insulating layer 210 or the first A surface layer containing an organic or inorganic dye may be selectively disposed on the upper surface or the lower surface of the electrically insulating layer 210. Among them, polycarbonate-polyester alloy (PC-Polyester Alloy) can be polycarbonate-polyethylene terephthalate alloy (PC-PET Alloy), polycarbonate-diol modified terephthalic acid PC-PETG Alloy, polycarbonate-polybutylene terephthalate alloy (PC-PBT Alloy). In one embodiment, fluoroplastics may be added to the surface layer, or an organic or inorganic dye such as barium sulfate (BaSO ₄ ) or calcium carbonate may be selectively added to the interlayer of the first electrically insulating layer 210. CaCO ₃ ), titanium dioxide (TiO 2 ) or carbon black, or fluoroplastics.

In addition, referring to FIG. 5A, a moisture-resistant material layer 212 may be selectively disposed on the upper surface of the first electrical insulating layer 210, and the material thereof may be ethylene vinyl alcohol (EVOH) or polyamine. (polyamide, PA) or polyvinyl dichloride (PVDC).

In the present invention, a moisture-resistant material layer 212 may be selectively disposed on at least one surface of the first electrical insulating layer 210, and the material thereof is ethylene and vinyl alcohol (EVOH), polyamine ( Polyamide, PA) or polyvinyl dichloride (PVDC). As shown in FIG. 5A, the moisture resistant material layer 212 is disposed on the upper surface of the first electrical insulating layer 210. As shown in FIG. 5B, the moisture resistant material layer 212 is disposed on the lower surface of the first electrical insulating layer 210. Moreover, as shown in FIG. 5C, the moisture resistant material layer 212 can be simultaneously disposed on the upper surface of the first electrically insulating layer 210.

Referring to FIG. 6, in an embodiment, the electrically insulating layer 200 is also a three-layer stacked structure. The structure includes: a first electrically insulating layer 210 is in contact with the sealing material layer 300 (shown in FIG. 2); a second electrically insulating layer 220 is stacked under the first electrically insulating layer 210; and a third electrical insulation Layer 230 is stacked under second electrically insulating layer 220. The material of the first electrical insulating layer 210 is selected from the group consisting of polyethylene terephthalate (PET), polycarbonate (PC) or polycarbonate-polyester alloy (PC-Polyester Alloy). ). Among them, polycarbonate-polyester alloy (PC-Polyester Alloy) can be polycarbonate-polyethylene terephthalate alloy (PC-PET Alloy), polycarbonate-diol modified terephthalic acid PC-PETG Alloy, polycarbonate-polybutylene terephthalate alloy (PC-PBT Alloy). The second electrically insulating layer 220 serves as a moisture resistant layer and is made of a material selected from the group consisting of aluminum foils. The material of the third electrical insulating layer 230 is fluoroplastics. In an embodiment, nano-clay may also be selectively added to the first electrically insulating layer 210 or the third electrically insulating layer 230.

Referring to FIG. 5D and FIG. 5E , in the present invention, the combination of the electrical insulating layer 200 is not limited to the above description, and may be changed according to the designer's requirements. For example, two layers of the first electrically insulating layer 210 may be disposed and matched with a wet resistance. The material layer 212 is combined with the two layers and with the second electrically insulating layer 220 to form an electrically insulating layer 200, as shown in FIG. 5D. In addition, the first electrical insulating layer 210, a moisture resistant material layer 212, a first electrical insulating layer 210 and a moisture resistant material layer 212 are sequentially arranged N times and selectively combined with the second electrically insulating layer 220, as shown in the figure. 5E is shown.

Please refer to FIG. 7 , which is a schematic diagram of a method for fabricating a back plate structure of a solar panel module according to an embodiment of the present invention. In the present embodiment, the method includes the steps of: providing an electrically insulating layer 200; and extruding a sealing material layer 300 directly from the die 500 onto the electrically insulating layer 200 by a hot melt extrusion method. The upper surface of the sealing material layer 300 has a surface embossed structure. In various embodiments, the electrically insulating layer 200 can be a single layer or a multi-layer structure, and if it is a multi-layer structure, it can be formed by adhesive bonding or co-extrusion molding. Further, the sealing material layer 300 may have a single layer or a multilayer structure, and if it is a multilayer structure, it may be formed by co-extrusion.

Although the sealing material layer and the electrical insulating layer of the present invention are co-extruded products, since the melting temperatures of the two materials are not the same, it is impossible to co-extend with the same mold. Therefore, by using different die forming methods, the electrical insulating layer is first pressed together, and then the sealing material layer is directly formed on the electrical insulating layer, so that the back plate structure of the low shrinkage composite material can be obtained. Further, when the electrically insulating layer is formed by a combination of adhesives, although not mentioned or illustrated in the foregoing description, it is understood that the layers and layers may be combined with an additional bonding agent or adhesive.

In the present invention, the sealing material layer is directly formed on the electrically insulating layer. A cross-linking agent can be added to the sealing material layer. Therefore, when the backing plate is subjected to the pressing process of the solar panel module package, the cross-linking is generated due to the pressing temperature, and the solar cell module can be directly packaged and protected. When the sealing material layer is a multi-layer combination, different layers can be made to have different degrees of crosslinking, so that the press-crossing rate can be controlled and the stress residue of rapid cross-linking can be eliminated. Further, an organic or inorganic material may be added in a single layer or in different layers to form a light reflecting layer or a light shielding layer. If the sealing material layer uses EVA, its high content of vinyl acetate provides excellent transparency. The surface of the sealing material layer of the invention has a special embossing shape design. When the pressing process is performed, the sealing material layer flows and covers the solar cell module by melting, and the air bubbles are discharged due to the material flow under the suction negative pressure environment. . A chemical bond can be added to the material of the sealing material layer, so that a subsequent reaction can be produced during the pressing process. The sealing material layer may also be added with a yellowing resistant additive to prevent cracking or yellowing of the long-term temperature reaction. In addition, an ultraviolet absorber may be added to prevent the strong ultraviolet light from damaging the material of the decomposition back sheet after exposure to sunlight.

In summary, the present invention integrates the sealing material layer and the electrically insulating layer into a composite backing plate by a hot melt extrusion method, without the need for additional paint sticking and omitting the several-day ripening step required for coating the adhesive layer and the product. The warpage value is low; the flat structure of the back plate can reduce the probability of fragmentation due to the difference in height, and the low shrinkage rate can also reduce the probability of chipping and the badness of the solar cell module circuit; and can reduce the air layer when the package is superposed. Produced with a faster pumping rate and a better layer adhesion.

The embodiments described above are merely illustrative of the technical spirit and the features of the present invention, and the objects of the present invention can be understood by those skilled in the art, and the scope of the present invention cannot be limited thereto. That is, the equivalent variations or modifications made by the spirit of the present invention should still be included in the scope of the present invention.

100‧‧‧Solar battery module

110‧‧‧ thermoplastic layer

120‧‧‧glass

130‧‧‧ Backplane

200‧‧‧Electrical insulation

210‧‧‧First electrical insulation

212‧‧‧Dampproof material layer

220‧‧‧Second electrical insulation

230‧‧‧ Third electrical insulation

300‧‧‧Sealing material layer

310‧‧‧First sealing material layer

320. . . Second sealing material layer

330. . . Third sealing material layer

Figure 1 is a schematic view of a conventional solar panel module.

2 is a schematic diagram of an embodiment of the present invention.

3A and 3B are schematic views of different embodiments of the present invention.

Figure 4 is a schematic illustration of an embodiment of the invention.

5A, 5B, 5C, 5D and 5E are schematic views of different embodiments of the present invention.

Figure 6 is a schematic illustration of an embodiment of the invention.

Figure 7 is a schematic illustration of an embodiment of the invention.

200. . . Electrical insulation

300. . . Sealing material layer

Claims (22)

A back sheet structure of a solar panel module comprising: an electrically insulating layer; and a layer of sealing material directly formed on the electrically insulating layer by an extrusion method and a surface of the sealing material layer The system has a surface embossed structure. The back sheet structure of the solar panel module according to claim 1, wherein the material of the sealing material layer is a cross-linked packaging material. The back sheet structure of the solar panel module according to claim 2, wherein the material of the sealing material layer is ethylene-vinyl acetate copolymer (EVA). The back sheet structure of the solar panel module according to claim 1, wherein the material of the sealing material layer is a polyvinyl butyral resin (PVB). The back sheet structure of the solar panel module of claim 1, wherein the sealing material layer is a multi-layered structure; and the material of the first sealing material layer having the surface embossing structure is selected from the group consisting of ethylene-acetic acid a vinyl ester copolymer or a polyvinyl butyral resin; and a second sealing material layer laminated under the first sealing material layer is selected from the group consisting of ethylene-vinyl acetate copolymer (ethylene-vinyl acetate copolymer, EVA), Polyvinyl Butyral (PVB), Polyolefins, Thermoplastic elastomer (TPE), such as thermoplastic elastomer (TPO), thermoplastic vulcanizate ( Thermoplastic Vulcanizates, TPV), fluorocarbon rubber, fluoro rubber. The back sheet structure of the solar panel module of claim 5, wherein a material of a third sealing material layer stacked under the second sealing material layer is selected from the group consisting of ethylene-vinyl acetate copolymer or polyethylene. Butyraldehyde resin. The back sheet structure of the solar panel module of claim 1, wherein the electrically insulating layer is a weather film. The back sheet structure of the solar panel module of claim 1, wherein the electrically insulating layer is made of fluoroplastics. The back sheet structure of the solar panel module according to claim 1, wherein the material of the electrical insulating layer The material of (fluoroplastics) may be selected from the group consisting of Poly-Vinyl Fluoride (PVF), polyvinylidene fluoride (PVDF), ethylene-tetrafluoroethylene (ETFE), tetrafluoroethylene and hexafluoropropylene. Perfluoronated ethylene propylene copolymer (EFEP), polypropylene (PP), polycarbonate (PC) or nylon blended with ethylene and vinyl alcohol copolymer (Nylon-EVOH). The back sheet structure of the solar panel module of claim 1, wherein the electrically insulating layer is made of a thermoplastic elastomer (TPE). The back sheet structure of the solar panel module of claim 10, wherein the thermoplastic rubber elastomer is selected from the group consisting of a thermoplastic elastomer (TPO), such as ethylene propylene diene (ethylene propylene diene). Terpolymer rubber, EPDM), ethylene propylene rubber (EPR), thermoplastic vulcanizates (TPV), fluorocarbon rubber, fluoroelastomer rubber. A backplane structure of a solar panel module includes: an electrically insulating layer is a multi-layered structure comprising: a first electrically insulating layer in contact with the layer of sealing material, the material of which is selected from the group consisting of polyterephthalic acid a polyethylene terephthalate (PET), a polycarbonate (PC) or a polycarbonate-polyester alloy; a second electrically insulating laminate is disposed under the first electrically insulating layer, Used as a moisture resistant layer and its material is selected from aluminum foil; and a third electrically insulating laminate is placed under the second electrically insulating layer, the material of which is fluoroplastics; and a seal The material layer is directly formed on the electrically insulating layer by a hot melt extrusion method and the surface of the sealing material layer has a surface embossed structure. A backplane structure of a solar panel module includes: an electrically insulating layer is a multi-layered structure comprising: a first electrically insulating layer in contact with the layer of sealing material, used as a moisture resistant layer; The second electrically insulating laminate is disposed under the first electrically insulating layer and is made of fluoroplastic and selected from the group consisting of Poly-Vinyl Fluoride (PVF), polyvinylidene fluoride (PVDF), and ethylene-tetrafluoroethylene. Ethylene-tetrafluoroethylene (ETFE) Or a copolymer of tetrafluoroethylene and hexafluoropropylene (EFEP); and a layer of sealing material directly formed on the electrically insulating layer by a hot melt extrusion method and the sealing material layer The upper surface has a surface embossed structure. The back sheet structure of the solar panel module of claim 13, wherein the first electrically insulating layer is made of a polymer. The back sheet structure of the solar panel module of claim 13, wherein the first electrical insulating layer is made of a thermoplastic elastomer (TPE), a thermoplastic elastomer (TPO) or a thermoplastic. Vulcanized rubber (Thermoplastic Vulcanizates, TPV). The back sheet structure of the solar panel module of claim 13, wherein the first electrical insulating layer is made of polyethylene terephthalate (PET) or polycarbonate (PC). . The back sheet structure of the solar panel module according to claim 16, wherein an organic or inorganic dye such as barium sulfate (BaSO ₄ ), calcium carbonate (CaCO ₃ ), titanium dioxide (TiO ₂ ) or carbon black is selectively added ( Carbon black) is within the first electrically insulating layer. The back sheet structure of the solar panel module of claim 16, wherein an organic or inorganic dye such as barium sulfate (BaSO ₄ ), calcium carbonate (CaCO ₃ ), or titanium dioxide (TiO ₂ ) may be disposed on the first electrically insulating layer. ) or carbon black. The back sheet structure of the solar panel module of claim 16, wherein a moisture-resistant material layer is selectively disposed on at least one surface of the first electrical insulating layer, and the material is ethylene and a vinyl alcohol copolymer ( Ethylene vinyl alcohol (EVOH), polyamide (PA) or polyvinyl dichloride (PVDC). The back sheet structure of the solar panel module of claim 13, wherein the first electrically insulating layer is made of a polycarbonate-polyester alloy. The back sheet structure of the solar panel module according to claim 20, wherein an organic or inorganic dye such as barium sulfate (BaSO ₄ ), calcium carbonate (CaCO ₃ ), titanium dioxide (TiO 2 ) or carbon black (carbon) is selectively added. Black) is within the first electrically insulating layer. The backplane structure of the solar panel module of claim 20, wherein the A moisture-resistant material layer is disposed on the upper surface of the first electrical insulating layer, and the material thereof is ethylene vinyl alcohol (EVOH), polyamide (PA) or polyvinyl dichloride (PVDC). ).