ENCAPSULATION ADHESIVE FILM FOR SOLAR CELL AND PREPARATION METHOD AND USE THEREFOR

Abstract

The present disclosure relates to an encapsulation adhesive film for a solar cell, comprising a transparent layer in contact with a cell sheet, and a first adhesive film layer in contact with the transparent layer, wherein raw materials of the first adhesive film layer comprise the following components: a resin and a colored filler with a mass ratio of 3 to 25:1, a cross-linking agent accounting for 0.1% to 5% of the total mass of the resin and the colored filler, an auxiliary cross-linking agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, a coupling agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, a light stabilizer accounting for 0.1% to 1% of the total mass of the resin and the colored filler, and a photo initiator accounting for 0.1% to 5% of the total mass of the resin and the colored filler. The present disclosure can effectively prevent a white substance from overflowing.

Claims

1. An encapsulation adhesive film for a solar cell comprising a transparent layer in contact with a cell sheet, and a first adhesive film layer in contact with the transparent layer, wherein a composition of the first adhesive film layer comprises: a resin and a colored filler with a mass ratio of 3 to 25:1, a cross-linking agent accounting for 0.1% to 5% of the total mass of the resin and the colored filler, an auxiliary cross-linking agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, a coupling agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, a light stabilizer accounting for 0.1% to 1% of the total mass of the resin and the colored filler, and a photo initiator accounting for 0.1% to 5% of the total mass of the resin and the colored filler.

2. The encapsulation adhesive film for a solar cell according to claim 1, wherein the mass ratio of the resin and the colored filler in the first adhesive film layer is 3 to 5:1.

3. The encapsulation adhesive film for a solar cell according to claim 1 comprising a second adhesive film layer in contact with a back-sheet or a glass.

4. The encapsulation adhesive film for a solar cell according to claim 3 comprising one or more third adhesive film layers arranged between the first adhesive film layer and the second adhesive film layer.

5. The encapsulation adhesive film for a solar cell according to claim 3, wherein, a composition of the second adhesive film layer comprises a resin and a colored filler with a mass ratio of 15 to 25:1.

6. The encapsulation adhesive film for a solar cell according to claim 5, wherein the composition of the second adhesive film layer comprises a cross-linking agent accounting for 0.1% to 5% of the total mass of the resin and the colored filler, an auxiliary cross-linking agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, a coupling agent accounting for 0.1% to 1% of the total mass of the resin and the colored filler, and a light stabilizer accounting for 0.1% to 1% of the total mass of the resin and the colored filler.

7. The encapsulation adhesive film for a solar cell according to claim 1, wherein a thickness of the transparent layer is 20 to 60 microns.

8. The encapsulation adhesive film for a solar cell according to claim 1, wherein a composition of the transparent layer comprises a resin, a cross-linking agent accounting for 0.1% to 5% of the mass of the resin, an auxiliary cross-linking agent accounting for 0.1% to 1% of the mass of the resin, a coupling agent accounting for 0.1% to 1% of the mass of the resin, and a light stabilizer accounting for 0.1% to 1% of the mass of the resin.

9. The encapsulation adhesive film for a solar cell according to claim 1, wherein the resin is selected from the group consisting of EVA, POE, PVB, and combinations thereof.

10. The encapsulation adhesive film for a solar cell according to claim 1, wherein the colored filler is selected from the group consisting of titanium dioxide, calcium carbonate, silicon dioxide, aluminum oxide, zinc-titanium whites, and combinations thereof.

11. The encapsulation adhesive film for a solar cell according to claim 1, wherein the photo initiator is selected from the group consisting of 2-hydroxy-2-methyl-1-phenyl-1-propanon, 1-hydroxycyclohexyl phenyl ketone, benzophenone, diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, 2-benzyl-2-(dimethylamino)-1-(4-morpholino phenyl) butanone, 2-hydroxy-1-(4-(2-hydroxy-2-methylpropionylphenyl) benzyl)-2-methyl-1-propanon, macromolecular photoinitiators thioxanthones, visible-light photo initiator camphor quinone, and combinations thereof.

12. The encapsulation adhesive film for a solar cell according to claim 1, wherein the cross-linking agent is selected from the group consisting of tert-butyl peroxy 2-ethylhexyl carbonate, t-butyl peroxy-isopropyl carbonate, dibenzoyl peroxide, dicumyl peroxide, 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane, cyclohexanone peroxide, tert-butyl hydroperoxide, tert-butyl peroxybenzoate, tert-butyl peroxyacetate, di-(4-tert-butylcyclohexyl) peroxybicarbonate, tert-butyl 3,5,5-trimethylperoxyhexanoate, triallyl isocyanate, and combinations thereof.

13. The encapsulation adhesive film for a solar cell according to claim 1, wherein the auxiliary cross-linking agent is selected from the group consisting of trimethylolpropane triacrylate, 2-trimethylolpropane tetraacrylate, ethoxylated trimethylolpropane triacrylate, ethoxylated trimethylolpropane triacrylate, propoxylated trimethylolpropane triacrylate, and combinations thereof.

14. The encapsulation adhesive film for a solar cell according to claim 1, wherein the coupling agent is selected from the group consisting of 3-methacryloxypropylmethyltrimethoxysilane, (3-glycidylpropyl)trimethoxysilane, vinyltrimethoxysilane, 3-amimopropyltriethoxysilane, vinyltrimethoxysilane, and combinations thereof.

15. The encapsulation adhesive film for a solar cell according to claim 1, wherein the light stabilizer is selected from the group consisting of bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate, poly(4-hydroxy-2,2,6,6 -tetramethyl-1-piperidine ethanol-alt-1,4-butanedioic acid), poly-{[6[(1,1,3,3-tetramethylbutyl)-imino]-1,3,5-triazine-2,4-diyl][2-(2,2,6,6-tetramethylpiperidyl)-nitrilo]-hexamethylene-[4-(2,2,6,6-tetramethylpiperidyl)- amino], and combinations thereof.

16. A preparation method of the encapsulation adhesive film for a solar cell according to claim 1 comprising following steps performed successively: Step (1), after separately preparing the raw materials of the first adhesive film layer and the transparent layer, tape casting through an extruder to form films; Step (2), on the side where the transparent layer is, irradiating through a UV lamp so that UV passes through the transparent layer to reach the first adhesive film layer and promotes a crosslinking reaction on the surface of the first adhesive film layer; Step (3): after cooling, pulling and winding to obtain an encapsulation adhesive film for a solar cell.

17. The preparation method according to claim 16, wherein a processing temperature of Step (1) is 60to 110 C.

18. The preparation method according to claim 16, wherein in Step (3), after three-roll setting, cooling and winding are performed.

19. The preparation method according to claim 16, wherein a cooling temperature of Step (3) is 20 to 50 C.

20. A solar cell comprising Use of the encapsulation adhesive film for a solar cell according to claim 1 any one of claims 1 to 15 in the solar cell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] FIG. 1 is a schematic structure diagram of the present disclosure;

[0048] wherein, 1transparent layer; 2first adhesive film layer; 3second adhesive film layer.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0049] In the following, the present disclosure is further explained in detail combining with specific embodiments, but the present disclosure is not limited to the following embodiments. The implementation conditions adopted in the embodiments can be further adjusted according to different requirements of specific use, and the implementation conditions not specified are the conventional conditions in the industry. All other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protective scope of the present disclosure.

Embodiment 1

[0050] The thickness of the transparent layer 1 was 50 microns, and its raw materials components were, EVA: 100 kg; tert-butyl peroxy 2-ethylhexyl carbonate: 0.6 kg; triallyl isocyanate: 0.8 kg; trimethylolpropane triacrylate: 0.6 kg; 3-methacryloxypropylmethyltrimethoxysilane: 0.5 kg;

[0051] bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate: 0.2 kg.

[0052] The thickness of the first adhesive film layer 2 was 300 microns, and its raw materials components were, EVA: 82 kg; titanium dioxide: 18 kg; tert-butyl peroxy 2-ethylhexyl carbonate:0.5 kg; 2-hydroxy-2-methyl-1-phenyl-1-propanon: 1.2 kg; triallyl isocyanate: 0.7 kg; trimethylolpropane triacrylate: 0.5 kg; 3-methacryloxypropylmethyltrimethoxysilane: 0.4 kg; bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate: 0.3 kg.

[0053] The thickness of the second adhesive film layer 3 was 50 microns, and its raw materials components were, EVA: 94 kg; titanium dioxide: 6 kg; tert-butyl peroxy 2-ethylhexyl carbonate: 0.8 kg; triallyl isocyanate: 0.9 kg; trimethylolpropane triacrylate: 0.4 kg; 3-methacryloxypropylmethyltrimethoxysilane: 0.5 kg; bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate: 0.6 kg.

[0054] The preparation method was: Step (1): the raw materials of the first adhesive film layer 2, the second adhesive film layer 3 and the transparent layer 1 were separately and evenly mixed, and then plastified by a co-extrusion casting machine, and extruded and casted into a film by a T-shaped die, and the processing temperature was set to 80 C.;

[0055] Step (2): after exiting the die head, on the side where the transparent layer 1 was located, UV light was irradiated so that UV passed through the transparent layer 1 to the first adhesive film layer 2, and since the die head was just exited, the product was in a molten state and had a high temperature, and after being irradiated through the UV lamp, the photo initiator on the surface of the first adhesive film layer 2 generated free radicals, and the free radicals further induced a crosslinking reaction on the surface of the first adhesive film layer 2 to form a pre-crosslinked layer;

[0056] Step (3): the product processed in Step (2) was shaped through three-roll setting, and then cooled at 20 C., pulled and winded to obtain an encapsulation adhesive film for a solar cell.

Embodiment 2

[0057] It is basically the same as Embodiment 1, differing by that, the resin used in the first adhesive film layer, the second adhesive film layer, and the transparent layer was POE.

Embodiment 3

[0058] It is basically the same as Embodiment 2, differing by that, the photo initiator in the second adhesive film layer was 1-hydroxycyclohexyl phenyl ketone.

Embodiment 4

[0059] It is basically the same as Embodiment 2, differing by that, the photo initiator in the second adhesive film layer was benzophenone.

Embodiment 5

[0060] It is basically the same as Embodiment 2, differing by that, the photo initiator in the second adhesive film layer was 2-hydroxy-1-(4-(2-hydroxy-2-methylpropionylphenyl) benzyl)-2-methyl-1-propanon.

Embodiment 6

[0061] It is basically the same as Embodiment 2, differing by that, the photo initiator in the second adhesive film layer was 2-benzyl-2-(dimethylamino)-1-(4-morpholino phenyl) butanone.

Embodiment 7

[0062] It is basically the same as Embodiment 1, differing by that, the thickness of the transparent layer was 60 microns.

Embodiment 8

[0063] It is basically the same as Embodiment 1, differing by that, the thickness of the transparent layer was 40 microns.

Embodiment 9

[0064] It is basically the same as Embodiment 1, differing by that, the thickness of the transparent layer was 20 microns.

Embodiment 10

[0065] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, EVA was 75 kg; titanium dioxide was 25 kg.

Embodiment 11

[0066] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, EVA was 83 kg; titanium dioxide was 17 kg.

Embodiment 12

[0067] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, the addition amount of the photo initiator was 2 kg.

Embodiment 13

[0068] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, the addition amount of the photo initiator was 3 kg.

Embodiment 14

[0069] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, the addition amount of the photo initiator was 5 kg.

Embodiment 15

[0070] It is basically the same as Embodiment 1, differing by that, in the raw materials of the first adhesive film layer, the addition amount of the photo initiator was 0.5 kg.

Embodiment 16

[0071] It is basically the same as Embodiment 1, differing by that, in the raw materials of the second adhesive film layer, EVA was 94 kg; titanium dioxide was 6 kg.

Embodiment 17

[0072] It is basically the same as Embodiment 1, differing by that, in the raw materials of the second adhesive film layer, EVA was 96 kg; titanium dioxide was 4 kg.

Embodiment 18

[0073] It is basically the same as Embodiment 1, differing by that, the thickness of the first adhesive film layer was 350 microns, without a second adhesive film layer.

Embodiment 19

[0074] It is basically the same as Embodiment 1, differing by that, a conventional third white adhesive film layer with a thickness of 50 microns was provides between the first adhesive film layer and the second adhesive film layer.

Embodiment 20

[0075] It is basically the same as Embodiment 1, differing by that, in the first adhesive film layer, EVA was 90 kg; titanium dioxide was 10 kg.

[0076] Control 1

[0077] It is basically the same as Embodiment 1, differing by that, the thickness of the transparent layer was 70 microns.

[0078] Control 2

[0079] It is basically the same as Embodiment 1, differing by that, the thickness of the transparent layer was 10 microns.

[0080] The experimental data of the respective embodiments and controls are shown in Table 1.

[0081] The test methods of crosslinking degree, stripping strength and reflectivity in the present disclosure refer to GB/T29848-2013 (Chinese standard Ethylene-vinyl acetate copolymer (EVA) adhesive film for photovoltaic module encapsulation). The test method of assembly power refers to IEC61215 standard.

TABLE-US-00001 Adhesive film Stripping Stripping strength from strength Assembly Cross-linking back-sheet from glass Reflectivity Assembly Assembly Appearance after degree % N/cm N/cm % power W appearance DH1000H Embodiment 82.5 78 158 97.2 266.65 Good, no Good, no 1 overflow or obvious folds yellowing or delamination Embodiment 77.3 72 136 97.5 266.55 Good, no Good, no 2 overflow or obvious folds yellowing or delamination Embodiment 84.1 77 157 97.8 266.58 Good, no Good, no 3 overflow or obvious folds yellowing or delamination Embodiment 87.8 86 147 96.9 266.67 Good, no Good, no 4 overflow or obvious folds yellowing or delamination Embodiment 81.3 79 146 97.5 266.75 Good, no Good, no 5 overflow or obvious folds yellowing or delamination Embodiment 83.8 85 152 97.8 266.45 Good, no Good, no 6 overflow or obvious folds yellowing or delamination Embodiment 82.8 87 153 97.2 265.05 Good, no Good, no 7 overflow or obvious folds yellowing or delamination Embodiment 84.5 90 153 97.5 266.95 Good, no Good, no 8 overflow or obvious folds yellowing or delamination Embodiment 82.6 82 144 98.0 267.35 Good, no Good, no 9 overflow or obvious folds yellowing or delamination Embodiment 83.5 88 158 98.2 266.95 Good, no Good, no 10 overflow or obvious folds yellowing or delamination Embodiment 81.4 79 162 95.3 265.75 Good, no Good, no 11 overflow or obvious folds yellowing or delamination Embodiment 92.5 84 153 97.0 266.67 Good, no Good, no 12 overflow or obvious folds yellowing or delamination Embodiment 95.5 83 152 97.0 266.35 Good, no Good, no 13 overflow or obvious folds yellowing or delamination Embodiment 97.5 84 153 97.0 266.66 Good, no Good, no 14 overflow or obvious folds yellowing or delamination Embodiment 79.5 85 156 97.2 266.65 Good, no Good, no 15 overflow or obvious folds yellowing or delamination Embodiment 82.7 70 132 98.2 267.35 Good, no Good, no 16 overflow or obvious folds yellowing or delamination Embodiment 83.2 84 153 96.2 266.75 Good, no Good, no 17 overflow or obvious folds yellowing or delamination Embodiment 82.7 56 130 98.2 266.75 Good, no Good, no 18 overflow or obvious folds yellowing or delamination Embodiment 82.5 79 152 97.8 266.67 Good, no Good, no 19 overflow or obvious folds yellowing or delamination Embodiment 82.8 77 152 93.2 265.35 Good, no Good, no 20 overflow or obvious folds yellowing or delamination Control 1 83.7 77 153 96.3 264.15 Good, no Good, no overflow or obvious folds yellowing or delamination Control 2 82.7 75 150 98.2 268.65 Slight Good, no overflow of obvious the long yellowing or side of the delamination cell sheet Note: Assemblies in the table refer to solar cells.

[0082] The above detailed describes the present disclosure, and are intended to make those skilled in the art being able to understand the present disclosure and thereby implement it, and should not be concluded to limit the protective scope of this disclosure. Any equivalent variations or modifications according to the spirit of the present disclosure should be covered by the protective scope of the present disclosure.