Light-conversion photovoltaic packaging adhesive film with multi-layer structure, high binding power and low water vapor transmittance and manufacturing method of light-conversion photovoltaic packaging adhesive film

Abstract

The invention provides a light-conversion photovoltaic packaging adhesive film with a multi-layer structure, high binding power and low water vapor transmittance and a manufacturing method of the light-conversion photovoltaic packaging adhesive film, and belongs to the technical field of photovoltaic adhesive films. The multi-layer structure high-adhesion and low-water-vapor-transmittance light-conversion photovoltaic packaging adhesive film comprises a light conversion layer, the upper end of the light conversion layer is compounded with a high-adhesion and low-water-vapor-transmittance layer, and the lower end of the light conversion layer is compounded with a low-fluidity layer. According to the invention, the light conversion layer comprises the light conversion agent, so that the adhesive film enhances the absorption of ultraviolet rays, improves the light conversion efficiency and reduces the damage of the ultraviolet rays to a battery piece; the upper layer is a high-adhesion and low-water-vapor-transmittance layer, hydrophobic resin, an initiator, a binder, a water blocking agent and the like are added into the prepared raw materials, the requirements of customers for low water vapor transmittance and high adhesion are met, the lower layer is a low-fluidity layer, irradiation is performed in advance to reduce the fluidity of the adhesive film, and the requirement of customers for low fluidity is met.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic encapsulant technology, and relates to a multi-layered photovoltaic encapsulant film with high adhesion and low water vapor transmittance, and its manufacturing method. Background Technology

[0002] Photovoltaic encapsulant film, as a key encapsulation material for photovoltaic modules, offers advantages such as protecting solar cells and extending module lifespan. Therefore, the reliability of photovoltaic encapsulant film plays a crucial role in photovoltaic modules. Traditional photovoltaic encapsulant films primarily use ethylene-vinyl acetate copolymer (EVA resin) and ethylene-octene polymer (POE resin). EVA, due to the presence of polar groups in its chemical structure, suffers from significant defects such as high water vapor permeability, yellowing, and easy hydrolytic aging. In contrast, POE, with its stable carbon-carbon single bond structure and lack of hydrophilic groups, offers performance advantages over EVA. However, due to inherent defects (poor processing performance), POE is difficult to crosslink to achieve satisfactory crosslinking degrees. Excessive crosslinking agents, co-crosslinking agents, antioxidants, and other inorganic or organic compounds need to be added to the formulation. However, the residual excessive additives in the laminated film can lead to problems such as film yellowing and solar cell corrosion under high temperature and pressure. The solar spectrum is an absorption spectrum of different wavelengths, divided into visible and invisible light. Ultraviolet (UV) and infrared (IR) rays are invisible light, and UV rays reaching the Earth's surface can cause significant damage to solar cells, such as HJTs, which are not affected by UV radiation. A light-converting agent is an additive that converts absorbed high-energy UV light into low-energy visible light through internal transitions. Therefore, to improve the conversion efficiency of UV radiation and reduce its damaging effects on solar cells, this technology attempts to introduce a light-converting agent to solve problems such as low light conversion efficiency. Furthermore, to obtain a low-moisture-transmittance, high-adhesion photovoltaic light-converting film, this application aims to develop a multilayer photovoltaic light-converting film with low moisture transmittance and high adhesion. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a multi-layered photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, as well as its manufacturing method. This solves the problems of low light conversion efficiency and ultraviolet radiation damage to photovoltaic cells in existing photovoltaic modules, and meets the market's demand for improved photovoltaic module performance (adhesion and water vapor transmission rate).

[0004] The objective of this invention can be achieved through the following technical solutions:

[0005] A multi-layered photovoltaic encapsulating film with high adhesion and low water vapor transmission rate includes a light conversion layer, an upper layer with high adhesion and low water vapor transmission rate is laminated on the light conversion layer, and a low flowability layer is laminated on the lower end of the light conversion layer.

[0006] In the aforementioned multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, the light conversion layer comprises the following components: 100 parts of matrix resin, 0.2-2.0 parts of main initiator, 0.3-1.5 parts of co-initiator, 0.1-1.5 parts of binder, 0.01-0.6 parts of anti-aging agent, and 0.05-10 parts of light conversion agent;

[0007] The matrix resin is selected from one or more combinations of polyolefin elastomers, ethylene-vinyl acetate copolymers, polyethylene resins, polypropylene resins, vinyl polymer grafted polyether polyols, ethylene-acrylic acid copolymers, ethylene-methyl methacrylate copolymers, and ethyl-methacrylates.

[0008] The anti-aging agent is selected from one or more combinations of phenolic antioxidants, phosphite antioxidants, hindered amine light stabilizers, ultraviolet absorbers, and hydrolysis-resistant additives;

[0009] The main initiator is selected from one or more combinations of cumene peroxide, di-tert-butyl peroxide, dicumene hydrogen peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, 4,4-di(tert-amylperoxy)valerate, tert-butyl peroxy-2-ethylhexyl carbonate, ethyl 3,3-di(tert-butylperoxy)butyrate, tert-butyl peroxycarbonate-2-ethylhexyl, tert-(2-ethylhexyl)carbonate-tert-amyl peroxide, and benzoyl peroxide.

[0010] The co-initiator is selected from one or more combinations of triallyl isocyanurate, triallyl cyanurate, trimethylolpropane trimethacrylate, and diethylene glycol dimethacrylate.

[0011] The binder is selected from one or more combinations of KH570, KH550, propyltriethoxysilane isocyanate, vinyltriacetoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, vinyl-triethoxysilane, vinyl-tert-butyltriperoxide, amino silane coupling agents, epoxy silane coupling agents, and amino oligomers;

[0012] The light-converting agent is selected from one or more combinations of powdered light-converting agents (inorganic metal oxides, organic small molecules, rare earth complex light-converting agents), organic fluorescent dye light-converting agents, and organic complex light-converting agents.

[0013] In the above-mentioned multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, the high adhesion and low water vapor transmission rate layer comprises the following components: 100 parts of matrix resin, 0.1-3 parts of water-blocking agent, 1-49 parts of hydrophobic resin, 0.1-5 parts of binder, 0.2-2 parts of initiator, and 0.01-1.5 parts of co-initiator;

[0014] The matrix resin is selected from one or more of the following: ethylene-methyl methacrylate copolymer, ethyl methacrylate, polyolefin elastomer, ethylene-vinyl acetate copolymer, polyethylene, and polypropylene.

[0015] The hydrophobic resin is selected from one or more combinations of polyolefin grafted copolyamide, ionomer resin, vinylidene fluoride-acrylate, POE resin, polyethylene resin, EVOH resin, copolymer polypropylene, polypropylene-ethylene elastomer, thermoplastic phenolic resin, and thermoplastic epoxy resin.

[0016] The water-blocking agent is selected from one or more combinations of organosilicon oil, small molecule polysiloxane, sodium methylsilicate, POSS, nanocellulose, and titanium carbide;

[0017] The binder is selected from one or more combinations of KH570, KH550, propyltriethoxysilane isocyanate, vinyltriacetoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, vinyl-triethoxysilane, vinyl-tert-butyltriperoxide, amino silane coupling agents, epoxy silane coupling agents, and amino oligomers;

[0018] The initiator is selected from one or more combinations of cumene peroxide, di-tert-butyl peroxide, di-cumene hydrogen peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, 4,4-di(tert-amylperoxy)valerate, tert-butyl peroxy-2-ethylhexyl carbonate, ethyl 3,3-di(tert-butylperoxy)butyrate, tert-butyl peroxycarbonate-2-ethylhexyl, tert-(2-ethylhexyl)carbonate-tert-amyl peroxide, and benzoyl peroxide.

[0019] The co-initiator is selected from one or more combinations of triallyl isocyanurate, triallyl cyanurate, trimethylolpropane trimethacrylate, and diethylene glycol dimethacrylate.

[0020] In the aforementioned multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, the low flowability layer comprises the following components: 100 parts of matrix resin, 0.1-1.5 parts of main initiator, 0.1-2 parts of co-initiator, 0.1-2 parts of water-blocking agent, and 0.01-4 parts of binder.

[0021] The material selected for the low-flow layer is the same as that of the high-adhesion, high-low water vapor permeability layer.

[0022] In the aforementioned multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, the thickness of the low flowability layer is 40-220 μm.

[0023] A method for manufacturing a multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate includes the following steps:

[0024] S1: Mix the materials in the mixing tank according to the formula, pour the mixed materials into the casting extruder for melting, extrusion, two-roll calendering, cooling, trimming, cutting, and winding to obtain high adhesion, low water vapor transmission rate layer, low flowability layer and light conversion layer respectively.

[0025] S2: The low-flowability layer is pre-crosslinked by irradiation to reduce flowability;

[0026] S3: A high-adhesion, low-moisture-transmittance layer is combined with a light-converting layer. After combining, trimming, cutting, and winding, a double-layer photovoltaic film is obtained. The double-layer photovoltaic film is combined with a low-flowability layer. After combining, trimming, cutting, and winding, a three-layer photovoltaic film is obtained.

[0027] Compared with the prior art, the present invention has the following advantages:

[0028] The light-converting layer includes a light-converting agent, which enhances the absorption of ultraviolet light by the film, improves the light-converting efficiency, and reduces the damage of ultraviolet light to the solar cells. The upper layer is a high-adhesion, low-water-vapor-transmittance layer. Hydrophobic resin, initiator, binder, water-blocking agent, etc. are added to the raw materials to meet the customer's requirements for low water vapor transmission and high adhesion. The lower layer is a low-flow layer. The film is pre-irradiated to reduce its flowability and meet the customer's low-flowability requirements. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the present invention.

[0030] In the picture,

[0031] (1) High adhesion and low water vapor permeability layer; (2) Light conversion layer; (3) Low flowability layer. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0033] As shown in Table 1,

[0034]

[0035]

[0036]

[0037]

[0038] Table 2

[0039]

[0040]

[0041] In Examples 1-5, as the proportion of the light-converting agent in the formulation increases, the power gain gradually increases. When the mass ratio of the light-converting agent to the matrix resin is 0.15:100, the power reaches its maximum value. Further increasing the proportion of the light-converting agent leads to a decreasing power gain. Therefore, the ratio of the light-converting agent to the matrix resin in the formulation needs to be strictly controlled within the optimal range.

[0042] Table 3

[0043]

[0044]

[0045] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0046] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Meanwhile, the word "and / or" throughout the text means including three solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0047] All of the above components are general standard parts or components known to those skilled in the art. Their structure and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0048] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A multi-layered photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, characterized in that, It includes a light-converting layer (2), the upper end of which is composited with a high-adhesion, low-water-vapor-transmittance layer (1), and the lower end of which is composited with a low-flow-rate layer (3).

2. The multilayer structure high-adhesion, low-moisture-transmittance photovoltaic encapsulating film according to claim 1, characterized in that, The light conversion layer (2) comprises the following components: 100 parts of matrix resin, 0.2-2.0 parts of main initiator, 0.3-1.5 parts of co-initiator, 0.1-1.5 parts of binder, 0.01-0.6 parts of anti-aging agent, and 0.05-10 parts of light conversion agent; The matrix resin is selected from one or more combinations of polyolefin elastomers, ethylene-vinyl acetate copolymers, polyethylene resins, polypropylene resins, vinyl polymer grafted polyether polyols, ethylene-acrylic acid copolymers, ethylene-methyl methacrylate copolymers, and ethyl-methacrylates. The anti-aging agent is selected from one or more combinations of phenolic antioxidants, phosphite antioxidants, hindered amine light stabilizers, ultraviolet absorbers, and hydrolysis-resistant additives; The main initiator is selected from one or more combinations of cumene peroxide, di-tert-butyl peroxide, dicumene hydrogen peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, 4,4-di(tert-amylperoxy)valerate, tert-butyl peroxy-2-ethylhexyl carbonate, ethyl 3,3-di(tert-butylperoxy)butyrate, tert-butyl peroxycarbonate-2-ethylhexyl, tert-(2-ethylhexyl)carbonate-tert-amyl peroxide, and benzoyl peroxide. The co-initiator is selected from one or more combinations of triallyl isocyanurate, triallyl cyanurate, trimethylolpropane trimethacrylate, and diethylene glycol dimethacrylate. The binder is selected from one or more combinations of KH570, KH550, propyltriethoxysilane isocyanate, vinyltriacetoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, vinyl-triethoxysilane, vinyl-tert-butyltriperoxide, amino silane coupling agents, epoxy silane coupling agents, and amino oligomers; The light-converting agent is selected from one or more combinations of powdered light-converting agents (inorganic metal oxides, organic small molecules, rare earth complex light-converting agents), organic fluorescent dye light-converting agents, and organic complex light-converting agents.

3. The multilayer structure high-adhesion, low-moisture-transmittance photovoltaic encapsulating film according to claim 1, characterized in that, The high-adhesion, low-water-vapor-permeability layer (1) comprises the following components: 100 parts matrix resin, 0.1-3 parts water-blocking agent, 1-49 parts hydrophobic resin, 0.1-5 parts binder, 0.2-2 parts initiator, 0.01-1.5 parts co-initiator; The matrix resin is selected from one or more of the following: ethylene-methyl methacrylate copolymer, ethyl methacrylate, polyolefin elastomer, ethylene-vinyl acetate copolymer, polyethylene, and polypropylene. The hydrophobic resin is selected from one or more combinations of polyolefin grafted copolyamide, ionomer resin, vinylidene fluoride-acrylate, POE resin, polyethylene resin, EVOH resin, copolymer polypropylene, polypropylene-ethylene elastomer, thermoplastic phenolic resin, and thermoplastic epoxy resin. The water-blocking agent is selected from one or more combinations of organosilicon oil, small molecule polysiloxane, sodium methylsilicate, POSS, nanocellulose, and titanium carbide; The binder is selected from one or more combinations of KH570, KH550, propyltriethoxysilane isocyanate, vinyltriacetoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, vinyl-triethoxysilane, vinyl-tert-butyltriperoxide, amino silane coupling agents, epoxy silane coupling agents, and amino oligomers; The initiator is selected from one or more combinations of cumene peroxide, di-tert-butyl peroxide, di-cumene hydrogen peroxide, 2,5-dimethyl-2,5-di-tert-butyl peroxide, 4,4-di(tert-amylperoxy)valerate, tert-butyl peroxy-2-ethylhexyl carbonate, ethyl 3,3-di(tert-butylperoxy)butyrate, tert-butyl peroxycarbonate-2-ethylhexyl, tert-(2-ethylhexyl)carbonate-tert-amyl peroxide, and benzoyl peroxide. The co-initiator is selected from one or more combinations of triallyl isocyanurate, triallyl cyanurate, trimethylolpropane trimethacrylate, and diethylene glycol dimethacrylate.

4. The multilayer structure high-adhesion, low-moisture-transmittance photovoltaic encapsulating film according to claim 1, characterized in that, The low-flow layer (3) comprises the following components: 100 parts matrix resin, 0.1-1.5 parts main initiator, 0.1-2 parts co-initiator, 0.1-2 parts water-blocking agent, and 0.01-4 parts binder; The material selected for the low-flow layer (3) is the same as that of the high-adhesion, high-low water vapor permeability layer (1).

5. The multilayer structure high-adhesion, low-moisture-transmittance photovoltaic encapsulating film according to claim 1, characterized in that, The thickness of the low-fluidity layer (3) is 40-220 μm.

6. A method for manufacturing a multilayer photovoltaic encapsulating film with high adhesion and low water vapor transmission rate, characterized in that, Includes the following steps: S1: Mix the materials in the mixing tank according to the formula, pour the mixed materials into the casting extruder for melting, extrusion, two-roll calendering, cooling, trimming, cutting, and winding to obtain a high adhesion and low water vapor transmission layer (1), a low flowability layer (3), and a light conversion layer (2). S2: Low fluidity layer (3) is pre-crosslinked by irradiation to reduce fluidity; S3: The high-adhesion, low-water-vapor-transmittance layer (1) is combined with the light-converting layer (2). After combining, trimming, cutting and winding, a double-layer photovoltaic film is obtained. The double-layer photovoltaic film is combined with the low-flow layer (3). After combining, trimming, cutting and winding, the three-layer photovoltaic film is obtained.

Images