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EP1904300A1 - Method for producing weather-resistant laminates for encapsulating solar cell systems - Google Patents

Method for producing weather-resistant laminates for encapsulating solar cell systems

Info

Publication number
EP1904300A1
EP1904300A1 EP06760782A EP06760782A EP1904300A1 EP 1904300 A1 EP1904300 A1 EP 1904300A1 EP 06760782 A EP06760782 A EP 06760782A EP 06760782 A EP06760782 A EP 06760782A EP 1904300 A1 EP1904300 A1 EP 1904300A1
Authority
EP
European Patent Office
Prior art keywords
weather
layer
carrier material
resistant
solar cell
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06760782A
Other languages
German (de)
French (fr)
Inventor
Nicole Depine
Joachim Danilko
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Isovoltaic AG
Original Assignee
Isovolta AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Isovolta AG filed Critical Isovolta AG
Publication of EP1904300A1 publication Critical patent/EP1904300A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31786—Of polyester [e.g., alkyd, etc.]

Definitions

  • the invention relates to a method for producing weather-resistant laminates for the encapsulation of solar cell systems and their use for the production of photovoltaic modules.
  • Photovoltaic modules are used for the generation of electrical energy from sunlight and consist of a laminate, which as a core layer, a solar cell system such. Contains silicon solar cells. This core layer is encased with encapsulating materials to provide protection against mechanical and weathering effects. These materials may consist of one or more layers, of glass and / or plastic films and / or plastic film composites.
  • fluoropolymer films are made in a separate process, for example by extrusion or tape casting. However, these methods are energy and costly.
  • Object of the present invention is therefore to provide a method of the type mentioned, with which weather-resistant laminates can be produced energy and cost-saving even in low layer thicknesses. Furthermore, despite the low layer thicknesses, a satisfactory weather resistance for outdoor use should be achieved.
  • a method for producing weather-resistant laminates for the encapsulation of solar cell systems is proposed, which is characterized in that at least one weather-resistant plastic layer is deposited on a carrier material is applied.
  • the invention further relates to the use of at least two laminates produced by the process according to the invention for producing a photovoltaic module, wherein the solar cell system is attached to one of the laminates.
  • This lamination process can be conducted continuously or discontinuously.
  • the encapsulation material 1, 1 shows the exemplary structure of a photovoltaic module 18 with the encapsulation material 1, 1 'produced by the method according to the invention.
  • the encapsulation material 1, 1 ' consist essentially of a weather-resistant layer 2, 2' and a carrier material 4, 4 ', to which an adhesion layer 5, 5' as adhesion promoter to the sealing layer 6, 6 'for the solar cell system 7 is adjacent.
  • FIG. 2 shows the exemplary structure of an encapsulation material 1, as shown in FIG. 1, in which an oxide layer 8 deposited from the vapor phase is provided to further improve the weathering properties.
  • Fig. 3 shows a possible device for applying the weather-resistant layer 2,2 'of a polymer solution.
  • 4 shows a possible laminating device for producing a pre-bond 17 for a photovoltaic module.
  • a weather-resistant layer 2, 2 'and an adhesion layer 5, 5' are applied to the substrate 4, 4 '.
  • Examples a) to d) represent possible variants for the selection of the components in the respective layers:
  • Weather-resistant layer 2, 2 ' selectively soluble fluoropolymers or fluorine copolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on the support materials 4, 4';
  • Adhesive layer 3, 3 ' polyurethane, polyester
  • Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
  • PET polyethylene terephthalate
  • PEN polyethylene naphthenate
  • ETFE ethylene tetrafluoroethylene copolymer
  • Adhesion Layer 5 polyurethane, polyacrylate or surface-treated fluoropolymer layer; Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
  • EVA ethylene vinyl acetate
  • PVB polyvinyl butyral
  • PMMA polymethyl methacrylate
  • Weather-resistant layer 2, 2 ' selectively soluble fluoropolymers or fluoropolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on pretreated support materials 4, 4';
  • Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
  • PET polyethylene terephthalate
  • PEN polyethylene naphthenate
  • ETFE ethylene tetrafluoroethylene copolymer
  • Adhesion Layer 5, 5 ' polyurethane, polyacrylate or surface-treated fluoropolymer layer;
  • Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
  • EVA ethylene vinyl acetate
  • PVB polyvinyl butyral
  • PMMA polymethyl methacrylate
  • polyurethane polyester or hot melt.
  • Weather-resistant layer 2, 2 ' selectively soluble / dispersible fluoropolymers or fluoropolymers, with a melting point below the laminating temperature for the direct coating on the support materials 4, 4';
  • Adhesive layer polyurethane, polyester
  • Support material 4, 4 ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
  • PET polyethylene terephthalate
  • PEN polyethylene naphthenate
  • ETFE ethylene tetrafluoroethylene copolymer
  • Adhesion layer 5, 5 1 polyurethane, polyacrylate or surface treated fluoropolymer layer;
  • Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
  • EVA ethylene vinyl acetate
  • PVB polyvinyl butyral
  • PMMA polymethyl methacrylate
  • polyurethane polyester or hot melt.
  • Weather-resistant layer 2, 2 ' selectively soluble / dispersible fluoropolymers or fluoropolymers, having a melting point below the laminating temperature for the direct Stratification on a pretreated substrate 4a, 4a ';
  • Support material 4a, 4a ' polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
  • PET polyethylene terephthalate
  • PEN polyethylene naphthenate
  • ETFE ethylene tetrafluoroethylene copolymer
  • Adhesion Layer 5, 5 ' polyurethane, polyacrylate or surface-treated fluoropolymer layer;
  • Sealing layer 6, 6 ' ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
  • EVA ethylene vinyl acetate
  • PVB polyvinyl butyral
  • PMMA polymethyl methacrylate
  • polyurethane polyester or hot melt.
  • a carrier material 4, 4 ' which is selected according to examples a) to d), is provided with a weather-resistant layer 2, 2'.
  • the polymers for the preparation of the weather-resistant layer 2, 2 ' are selected according to examples a) to d). If, as in examples c) and d), a weather-resistant layer, predominantly a fluoropolymer or fluorocopolymer, is used, a film uniform in its chemical constitution is produced. If, however, chemically different polymers are used, as stated in examples a) and b), it is also possible to use polymer mixtures for the weather-resistant layer 2, 2 '.
  • the polymer raw materials used are varied in their ratios such that the physical and / or chemical properties of the finished weather-resistant layer 2, 2 'can be modified or optimized as desired.
  • the support material can be pretreated before coating with the weather-resistant layer 2, 2 '.
  • the pretreatment can be carried out on the one hand by applying an additional adhesive and on the other hand by applying an inorganic oxide layer, preferably a silicon oxide layer, deposited from the vapor phase.
  • an inorganic oxide layer preferably a silicon oxide layer, deposited from the vapor phase.
  • a solvent halogen-free organic solvents are used for environmental and disposal reasons.
  • the solution or dispersion may further comprise dyes.
  • dyes During coating, it has also proven to be advantageous to use dispersions, since when preparing a dispersion, the solvent content can be substantially reduced.
  • a fluoropolymer is dissolved at 40-100 ° C. and a stirring speed of at least 2800 rpm by means of an intensive stirrer or dissolver under reflux in 2-butanone.
  • Diverse fillers or dyes, such as titanium dioxide or carbon black can be added to the solution up to a proportion of 35%, based on the fluoropolymer used, so that a dispersion is formed. This is applied to the carrier material 4, 4 ', for example a pre-treated PET film, via the application devices 11.
  • the layer thickness of the weather-resistant layer 2, 2 ' is controlled, which is for example in a range of 5 to 50 microns.
  • the thus coated material 4, 4 ' is then fed via the deflection rollers 9a to a dryer 12, in which the solvent used is evaporated at temperatures between 80 ° and 180 ° C. Exhaust air and temperature settings in the dryer are selected so that a bubble-free, dry coating is produced. The residual solvent content of 0.3-0.6% is used as a criterion for accurate temperature adjustment.
  • the carrier material 4, 4 'provided with the layer 2, 2' is further fed to the storage roll 13 via a deflection roller 9b and wound up on this.
  • the carrier material 4, 4 'provided on one side with the weather-resistant layer 2, 2' can now be coated on the still uncoated surface side with the adhesion layer 5, 5 1 .
  • This is done using the system shown in Fig. 3, wherein polyurethanes and fluoropolymers are used as starting materials.
  • the fluoropolymers may be chemically or physically surface treated after coating.
  • the lamination process is indeed a composite of the layers
  • the solar cell system 7 consisting of flexible solar cell types, is applied to the encapsulation material 1 '.
  • a further encapsulating material layer 1 is removed and fed to the solar cell system 7.
  • the material webs drawn off from the storage rolls 9 and 9a are each fed to a heating station 14 or 14a in which the encapsulation materials 1, 1 'are heated at least to the softening temperature of the sealing layer 6, 6'. This ensures the formation of a bond between the layers 1, 1 'on the one hand and the solar cell system 7 on the other hand in the nip of the calendering station 15.
  • the pre-bond is fed to a heating station 16.
  • the composite 17 for a photovoltaic module can be stored on the storage roll 9b and deducted accordingly.
  • the production is economical in terms of process, since the thickness of the weather-resistant layer 2, Z 'can be reduced and thus the proportion of relatively expensive fluoropolymers can be reduced.
  • the process can be carried out in-situ, which the process management much easier.
  • temperature ranges which are advantageously between 80 and 180 ° C. can be set so that energy-saving process control is also made possible.
  • the thickness of the weather-resistant layer 2, 2 ' can be adjusted.
  • this layer thickness a number of possible uses of the photovoltaic module using the encapsulation materials produced according to the invention are possible, ranging from small-scale power systems for emergency call or mobile homes to large-scale roof and façade systems as well as large-scale systems and solar power plants.

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  • Microelectronics & Electronic Packaging (AREA)
  • Computer Hardware Design (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Electromagnetism (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Laminated Bodies (AREA)
  • Photovoltaic Devices (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Coating Of Shaped Articles Made Of Macromolecular Substances (AREA)

Abstract

The invention relates to a method for producing weather-resistant laminates (1, 1') for encapsulating solar cell systems (7). The inventive method is characterised in that at least one weather-resistant plastic layer (2, 2') is applied to a carrier material (4, 4'). The inventive coating method is advantageous in that the relatively expensive starting products, which are normally used in the form of films, can be reduced in the thickness and numbers thereof. The inventive laminate, which is produced according to said method, can be used in a plurality of ways due to the controllable adjustment of the layer thickness of the weather-resistant layer (2, 2'), in particular in connection with the finished photovoltaic modules. Said uses range from small energy plants for emergency telephones or camping cars to large-surfaced roof and façade systems and also large plants and solar power stations.

Description

Verfahren zur Herstellung witterungsbeständiger Laminate für die Einkapselung von SolarzellensystemenProcess for the production of weather-resistant laminates for the encapsulation of solar cell systems
Die Erfindung betrifft ein Verfahren zur Herstellung witte- rungsbeständiger Laminate für die Einkapselung von Solarzellensystemen sowie deren Verwendung für die Herstellung photovoltaischer Module .The invention relates to a method for producing weather-resistant laminates for the encapsulation of solar cell systems and their use for the production of photovoltaic modules.
Photovoltaische Module dienen zur elektrischen Energieerzeugung aus Sonnenlicht und bestehen aus einem Laminat, welches als Kernschicht ein Solarzellensystem wie z.B. Siliziumsolarzellen enthält. Diese Kernschicht ist mit Einkapselungsmaterialien umhüllt, um einen Schutz gegen mechanische und witterungsbedingte Einflüsse zu gewährleisten. Diese Materialien können aus ein oder mehreren Schichten, aus Glas und/oder Kunststofffolien und/oder Kunststoff- folienverbunden bestehen.Photovoltaic modules are used for the generation of electrical energy from sunlight and consist of a laminate, which as a core layer, a solar cell system such. Contains silicon solar cells. This core layer is encased with encapsulating materials to provide protection against mechanical and weathering effects. These materials may consist of one or more layers, of glass and / or plastic films and / or plastic film composites.
Verfahren zur Herstellung witterungsbeständiger Folienlaminate für die Einkapselung von photovoltaischen Zellen sind aus der WO-A- 94/29106, WO-A-01/67523 sowie der WO-A-00/02257 bekannt. Das Solarzellensystem ist in diesen Modulen nicht nur gegen mechanische Beschädigung, sondern auch gegen Wasserdampf und insbesondere auch gegen Witterungseinflüsse geschützt. Deshalb werden im Einkaps- elungsmaterial vorwiegend witterungsbeständige Kunststoffe, wie Folien aus Fluorpolymeren eingesetzt.Methods for producing weather-resistant film laminates for the encapsulation of photovoltaic cells are known from WO-A-94/29106, WO-A-01/67523 and WO-A-00/02257. The solar cell system is protected in these modules not only against mechanical damage, but also against water vapor and in particular against the effects of weather. Therefore, weather-resistant plastics, such as films made of fluoropolymers, are used in the encapsulant material.
Diese Fluorpolymerfolien werden in einem separaten Verfahren, beispielsweise durch Extrusion oder Foliengießen hergestellt. Diese Verfahren sind allerdings energie- und kostenaufwändig.These fluoropolymer films are made in a separate process, for example by extrusion or tape casting. However, these methods are energy and costly.
Zudem ist die Herstellung der Fluorpolymerfolien auf Grund ihrer begrenzten Reißfestigkeit nur in bestimmten Mindestdicken möglich. Hier will die Erfindung Abhilfe schaffen.In addition, the production of the fluoropolymer films due to their limited tear resistance is possible only in certain minimum thicknesses. The invention aims to remedy this situation.
Aufgabe der vorliegenden Erfindung ist es daher, ein Verfahren der eingangs genannten Art anzugeben, mit welchem witterungsbeständige Laminate auch in geringen Schichtdicken energie- und kostenschonend hergestellt werden können. Weiters soll trotz der geringen Schichtdicken eine zufriedenstellende Witterungsbeständigkeit für die Außenanwendung erzielt werden.Object of the present invention is therefore to provide a method of the type mentioned, with which weather-resistant laminates can be produced energy and cost-saving even in low layer thicknesses. Furthermore, despite the low layer thicknesses, a satisfactory weather resistance for outdoor use should be achieved.
Erfindungsgemäß wird ein Verfahren zum Herstellen witterungsbeständiger Laminate für die Einkapselung von Solarzellensystemen vorgeschlagen, welches dadurch gekennzeichnet ist, dass auf ein Trägermaterial zumindest eine witterungsbeständige KunststoffSchicht aufgetragen wird.According to the invention, a method for producing weather-resistant laminates for the encapsulation of solar cell systems is proposed, which is characterized in that at least one weather-resistant plastic layer is deposited on a carrier material is applied.
Vorteilhafte Ausführungsformen des erfindungsgemäßen Verfahrens sind in den Unteransprüchen offenbart.Advantageous embodiments of the method according to the invention are disclosed in the subclaims.
Die Erfindung betrifft weiters die Verwendung zumindest zweier nach dem erfindungsgemäßen Verfahren hergestellten Laminate zum Herstellen eines photovoltaischen Moduls, wobei an einem der Laminate das Solarzellensystem angebracht wird. Dieses Laminierverfahren kann kontinuierlich oder diskontinuierlich geführt werden.The invention further relates to the use of at least two laminates produced by the process according to the invention for producing a photovoltaic module, wherein the solar cell system is attached to one of the laminates. This lamination process can be conducted continuously or discontinuously.
Die Erfindung wird im folgenden anhand beispielhafter Darstel- lungen - siehe Figuren 1 bis 4 - sowie möglicher Ausführungswege näher erläutert.The invention will be explained in more detail below with reference to exemplary representations - see FIGS. 1 to 4 - as well as possible execution paths.
Fig. 1 zeigt den beispielhaften Aufbau eines photovoltaischen Moduls 18 mit dem durch das erfindungsgemäße Verfahren hergestellte Ξinkapselungsmaterial 1, 1'. Das Einkapselungsmaterial 1, 1' be- stehen im wesentlichen aus einer witterungsbeständigen Schicht 2, 2' und einem Trägermaterial 4, 4', an welches eine Adhäsionsschicht 5, 5' als Haftvermittler zur Siegelschicht 6, 6' für das Solarzellensystem 7 angrenzt.1 shows the exemplary structure of a photovoltaic module 18 with the encapsulation material 1, 1 'produced by the method according to the invention. The encapsulation material 1, 1 'consist essentially of a weather-resistant layer 2, 2' and a carrier material 4, 4 ', to which an adhesion layer 5, 5' as adhesion promoter to the sealing layer 6, 6 'for the solar cell system 7 is adjacent.
Fig. 2 zeigt den beispielhaften Aufbau eines Einkapselungs- materials 1, wie in Fig. 1 dargestellt, bei welchem zur weiteren Verbesserung der Witterungseigenschaften eine aus der Dampfphase abgeschiedene Oxidschicht 8 vorgesehen ist.2 shows the exemplary structure of an encapsulation material 1, as shown in FIG. 1, in which an oxide layer 8 deposited from the vapor phase is provided to further improve the weathering properties.
Fig. 3 zeigt eine mögliche Vorrichtung zum Auftragen der witterungsbeständigen Schicht 2,2' aus einer Polymerlösung. Fig. 4 zeigt eine mögliche Laminiereinrichtung zur Herstellung eines Vorverbundes 17 für einen photovolatischen Modul.Fig. 3 shows a possible device for applying the weather-resistant layer 2,2 'of a polymer solution. 4 shows a possible laminating device for producing a pre-bond 17 for a photovoltaic module.
Zur Herstellung eines Einkapselungsmaterials 1 gemäß Fig. 1 bzw. Fig. 2 werden in einem ersten Verfahrensschritt auf das Trägermaterial 4, 4' eine witterungsbeständige Schichte 2, 2' und eine Adhäsionsschicht 5, 5' aufgetragen.In order to produce an encapsulation material 1 according to FIG. 1 or FIG. 2, in a first method step, a weather-resistant layer 2, 2 'and an adhesion layer 5, 5' are applied to the substrate 4, 4 '.
Die Beispiele a) bis d) geben mögliche Varianten für die Auswahl der Komponenten in den jeweiligen Schichten wieder:Examples a) to d) represent possible variants for the selection of the components in the respective layers:
Beispiel a) :Example a):
Witterungsbeständige Schicht 2, 2': Selektiv lösliche Fluor- polymere bzw. Fluor-Copolymere, Acrylate, Polyurethane, Silikone sowie Mischungen daraus für die Direktbeschichtung auf die Trägermaterialien 4, 4 ' ;Weather-resistant layer 2, 2 ': selectively soluble fluoropolymers or fluorine copolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on the support materials 4, 4';
Kleberschicht 3, 3': Polyurethan, Polyester;Adhesive layer 3, 3 ': polyurethane, polyester;
Trägermaterial 4, 4': Polyethylentherephthalat (PET), PoIy- ethylennaphthenat (PEN) , Ethylentetrafluorethylencopolymer (ETFE) sowie Co-Extrudate daraus in Form von Folien oder Folienverbunden, Aluminiumfolien in unterschiedlichen Dicken;Support material 4, 4 ': polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
Adhäsionsschicht 5, 5': Polyurethan, Polyacrylat oder oberflächenbehandelte Fluorpolymerschicht; Siegelschicht 6, 6': Ethylenvinylacetat (EVA), Polyvinylbuty- ral (PVB) , Ionomere, Polymethylmethacrylat (PMMA) , Polyurethan, Polyester oder Hot MeIt.Adhesion Layer 5, 5 ': polyurethane, polyacrylate or surface-treated fluoropolymer layer; Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
Beispiel b) :Example b):
Witterungsbeständige Schicht 2, 2': Selektiv lösliche Fluor- polymere bzw. Fluor-Copolymere, Acrylate, Polyurethane, Silikone sowie Mischungen daraus für die Direktbeschichtung auf vorbehandelte Trägermaterialien 4, 4';Weather-resistant layer 2, 2 ': selectively soluble fluoropolymers or fluoropolymers, acrylates, polyurethanes, silicones and mixtures thereof for the direct coating on pretreated support materials 4, 4';
Trägermaterial 4, 4': Polyethylentherephthalat (PET), PoIy- ethylennaphthenat (PEN) , Ethylentetrafluorethylencopolymer (ETFE) sowie Co-Extrudate daraus in Form von Folien oder Folienverbunden, Aluminiurafolien in unterschiedlichen Dicken;Support material 4, 4 ': polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
Adhäsionsschicht 5, 5': Polyurethan, Polyacrylat oder oberflächenbehandelte Fluorpolymerschicht;Adhesion Layer 5, 5 ': polyurethane, polyacrylate or surface-treated fluoropolymer layer;
Siegelschicht 6, 6': Ethylenvinylacetat (EVA), Polyvinylbuty- ral (PVB), Ionomere, Polymethylmethacrylat (PMMA), Polyurethan, Polyester oder Hot MeIt.Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
Beispiel c) :Example c):
Witterungsbeständige Schicht 2, 2': Selektiv lösli- che/dispergierfähige Fluorpolymere bzw. Fluor-Copolymere, mit einem Schmelzpunkt unterhalb der Laminiertemperatur für die Direktbeschichtung auf die Trägermaterialien 4, 4';Weather-resistant layer 2, 2 ': selectively soluble / dispersible fluoropolymers or fluoropolymers, with a melting point below the laminating temperature for the direct coating on the support materials 4, 4';
Kleberschicht : Polyurethan, Polyester;Adhesive layer: polyurethane, polyester;
Trägermaterial 4, 4': Polyethylentherephthalat (PET), PoIy- ethylennaphthenat (PEN) , Ethylentetrafluorethylencopolymer (ETFE) sowie Co-Extrudate daraus in Form von Folien oder Folienverbunden, Aluminiumfolien in unterschiedlichen Dicken;Support material 4, 4 ': polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
Adhäsionsschicht 5, 51: Polyurethan, Polyacrylat oder oberflächenbehandelte Fluorpolymerschicht;Adhesion layer 5, 5 1: polyurethane, polyacrylate or surface treated fluoropolymer layer;
Siegelschicht 6, 6': Ethylenvinylacetat (EVA), Polyvinylbuty- ral (PVB) , Ionomere, Polymethylmethacrylat (PMMA) , Polyurethan, Polyester oder Hot MeIt.Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
Beispiel d) :Example d):
Witterungsbeständige Schicht 2, 2': Selektiv lösli- che/dispergierfähige Fluorpolymere bzw. Fluor-Copolymere, mit einem Schmelzpunkt unterhalb der Laminiertemperatur für die Direktbe- Schichtung auf ein vorbehandeltes Trägermaterial 4a, 4a';Weather-resistant layer 2, 2 ': selectively soluble / dispersible fluoropolymers or fluoropolymers, having a melting point below the laminating temperature for the direct Stratification on a pretreated substrate 4a, 4a ';
Trägermaterial 4a, 4a': Polyethylentherephthalat (PET), PoIy- ethylennaphthenat (PEN), Ethylentetrafluorethylencopolymer (ETFE) sowie Co-Extrudate daraus in Form von Folien oder Folienverbunden, Aluminiumfolien in unterschiedlichen Dicken;Support material 4a, 4a ': polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene copolymer (ETFE) and co-extrudates thereof in the form of films or film composites, aluminum foils in different thicknesses;
Adhäsionsschicht 5, 5': Polyurethan, Polyacrylat oder oberflächenbehandelte Fluorpolymerschicht ;Adhesion Layer 5, 5 ': polyurethane, polyacrylate or surface-treated fluoropolymer layer;
Siegelschicht 6, 6': Ethylenvinylacetat (EVA), Polyvinylbuty- ral (PVB) , Ionomere, Polymethylmethacrylat (PMMA) , Polyurethan, Polyester oder Hot MeIt.Sealing layer 6, 6 ': ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt.
Ein Trägermaterial 4, 4', welches gemäß Bespiele a) bis d) ausgewählt wird, wird mit einer witterungsbeständigen Schicht 2, 2' versehen. Die Polymere für die Herstellung der witterungsbeständigen Schicht 2, 2' werden gemäß Beispiele a) bis d) ausgewählt. Wird dabei wie in Beispiel c) und d) angeführt, als witterungsbeständige Schicht, vorwiegend ein Fluorpolymer bzw. Fluorcopolymer eingesetzt, so wird ein in seiner chemischen Konstitution einheitlicher Film erzeugt. Werden allerdings chemisch unterschiedliche Polymere, wie in den Beispielen a) und b) angeführt, eingesetzt, so ist es auch möglich, Polymermischungen für die witterungsbeständige Schicht 2, 2' zu verwenden. Dabei werden die eingesetzten Polymerrohstoffe in ihren Verhältniszahlen derart variiert, dass die physikalischen und/oder chemischen Eigenschaften der endgefertigten witterungsbeständigen Schicht 2, 2' beliebig modifiziert bzw. optimiert werden kann.A carrier material 4, 4 ', which is selected according to examples a) to d), is provided with a weather-resistant layer 2, 2'. The polymers for the preparation of the weather-resistant layer 2, 2 'are selected according to examples a) to d). If, as in examples c) and d), a weather-resistant layer, predominantly a fluoropolymer or fluorocopolymer, is used, a film uniform in its chemical constitution is produced. If, however, chemically different polymers are used, as stated in examples a) and b), it is also possible to use polymer mixtures for the weather-resistant layer 2, 2 '. The polymer raw materials used are varied in their ratios such that the physical and / or chemical properties of the finished weather-resistant layer 2, 2 'can be modified or optimized as desired.
Zur Erhöhung der Witterungsbeständigkeit sowie auch zur Erhöhung der Verklebung gegenüber angrenzenden Verbundschichten kann das Trägermaterial vor dem Beschichten mit der witterungsbeständigen Schicht 2, 2' vorbehandelt werden. Die Vorbehandlung kann einerseits durch Auftragen eines zusätzlichen Klebers sowie anderseits durch Aufbringen einer aus der Dampfphase abgeschiedenen anorganischen Oxidschicht, vorzugsweise einer Siliziumoxidschicht erfolgen. Weiters ist es möglich, wie in Fig. 3 gezeigt, die Vorbehandlung des Trägermaterials 4, 4' mittels physikalischer Medien in der Anlage 10 durchzuführen. In der Folge wird das Trägermaterial 4, 4' zum Beschichten einem Auftragswerk 11 zugeführt, in welchem die witterungsbeständigen Kunststoffe in gelöster oder dispergierter Form vorliegen. Als Lösungsmittel werden aus Umwelt- sowie Entsorgungsgründen halogenfreie organische Lösungsmittel eingesetzt. Die Lösung oder Dispersion kann weiters Farbstoffe aufweisen. Beim Beschichten hat es sich weiters als vorteilhaft erwiesen, Dispersionen einzusetzen, da beim Herstellen einer Dispersion der Lösungsmittelanteil wesentlich reduziert werden kann. Beispielsweise wird ein Fluorpolymer bei 40-100 'C und einer Rührgeschwindigkeit von mindestens 2800 U/min mittels Intensivrührer oder Dissolver unter Rückfluss in 2-Butanon gelöst. Diverse Füllstoffe bzw. Farbstoffe, wie Titandioxid oder Ruß können der Lösung bis zu einem Anteil von 35 % bezogen auf das eingesetzte Fluorpolymer zugesetzt werden, sodass eine Dispersion gebildet wird. Diese wird über die Auftrags- anläge 11 auf das Trägermaterial 4, 4', beispielweise eine vorbehandelte PET-Folie aufgebracht. Durch Einstellen des Walzenspaltes in der Auftragsanlage 11 wird die Schichtdicke der witterungsbeständigen Schicht 2, 2' gesteuert, welche beispielsweise in einem Bereich von 5 bis 50 μm liegt. Das so beschichtete Material 4, 4' wird anschließend über die Umlenkrollen 9a einem Trockner 12 zugeführt, in welchem das eingesetzte Lösungsmittel bei Temperaturen zwischen 80° und 180° C verdampft. Abluft und Temperatureinstellungen im Trockner werden so gewählt, dass eine blasenfreie, trockene Be- schichtung entsteht. Der Restlösungsmittelgehalt von 0,3 - 0,6 % wird als Kriterium für die genaue Temperatureinstellung herangezogen.To increase the weathering resistance as well as to increase the adhesion to adjacent composite layers, the support material can be pretreated before coating with the weather-resistant layer 2, 2 '. The pretreatment can be carried out on the one hand by applying an additional adhesive and on the other hand by applying an inorganic oxide layer, preferably a silicon oxide layer, deposited from the vapor phase. Furthermore, it is possible, as shown in FIG. 3, to carry out the pretreatment of the carrier material 4, 4 'by means of physical media in the system 10. As a result, the carrier material 4, 4 'for coating a commissioned work 11 supplied, in which the weather-resistant plastics are present in dissolved or dispersed form. As a solvent halogen-free organic solvents are used for environmental and disposal reasons. The solution or dispersion may further comprise dyes. During coating, it has also proven to be advantageous to use dispersions, since when preparing a dispersion, the solvent content can be substantially reduced. For example, a fluoropolymer is dissolved at 40-100 ° C. and a stirring speed of at least 2800 rpm by means of an intensive stirrer or dissolver under reflux in 2-butanone. Diverse fillers or dyes, such as titanium dioxide or carbon black, can be added to the solution up to a proportion of 35%, based on the fluoropolymer used, so that a dispersion is formed. This is applied to the carrier material 4, 4 ', for example a pre-treated PET film, via the application devices 11. By adjusting the nip in the applicator 11, the layer thickness of the weather-resistant layer 2, 2 'is controlled, which is for example in a range of 5 to 50 microns. The thus coated material 4, 4 'is then fed via the deflection rollers 9a to a dryer 12, in which the solvent used is evaporated at temperatures between 80 ° and 180 ° C. Exhaust air and temperature settings in the dryer are selected so that a bubble-free, dry coating is produced. The residual solvent content of 0.3-0.6% is used as a criterion for accurate temperature adjustment.
Das mit der Schicht 2, 2' versehene Trägermaterial 4, 4' wird weiters über eine Umlenkrolle 9b der Aufbewahrungsrolle 13 zugeführt und auf dieser aufgewickelt. In einem weiteren Verfahrensschritt kann nunmehr das einseitig mit der witterungsbeständigen Schicht 2, 2' versehene Trägermaterial 4, 4' an der noch unbeschichteten Oberflächenseite mit der Adhäsionsschicht 5, 51 beschichtet werden. Dies erfolgt unter Verwendung der in Fig. 3 gezeigten Anlage, wobei als Ausgangsprodukte Polyu- rethane sowie Fluorpolymere dienen. Die Fluorpolymere können nach dem Beschichten chemisch oder physikalisch oberflächenbehandelt werden.The carrier material 4, 4 'provided with the layer 2, 2' is further fed to the storage roll 13 via a deflection roller 9b and wound up on this. In a further method step, the carrier material 4, 4 'provided on one side with the weather-resistant layer 2, 2' can now be coated on the still uncoated surface side with the adhesion layer 5, 5 1 . This is done using the system shown in Fig. 3, wherein polyurethanes and fluoropolymers are used as starting materials. The fluoropolymers may be chemically or physically surface treated after coating.
Für die Herstellung des Einkapselungsmaterials 1, I1 wie in Fig. 1 gezeigt, wird nunmehr die Rollenware diskontinuierlich abge- längt und in üblichen Laminierverfahren mit der Siegelschicht 6, welche gemäß Beispiele a) bis d) ausgewählt werden kann, verbunden.For the production of the encapsulating material 1, I 1, as shown in FIG. 1, the rolls are now discontinuously cut off and joined in conventional laminating processes with the sealing layer 6, which can be selected according to Examples a) to d).
Durch das Laminierverfahren ist zwar ein Verbund der SchichtenThe lamination process is indeed a composite of the layers
2, 4, 5 und 6 bzw. 2', 4', 5' und 6' gegeben, jedoch erfolgt die weitere Aushärtung der im Verbund eingesetzten Kunststoffe bei der Endfertigung des photovoltaischen Moduls 17, welche, wie in Fig. 4 gezeigt, beispielsweise durch ein sogenanntes Rolle zu Rolle Verfahren erfolgen kann.2, 4, 5 and 6 or 2 ', 4', 5 'and 6' given, however, the further curing of the plastics used in the composite in the final production of the photovoltaic module 17, which, as shown in FIG shown, for example, by a so-called roll to roll process can be done.
Dabei wird beispielsweise am Einkapselungsmaterial 1' das Solarzellensystem 7, bestehend aus flexiblen Solarzelltypen, an- gebracht. Von der gegenüberliegenden Aufbewahrungsrolle 9 wird eine weitere Einkapselungsmaterialschicht 1 abgezogen und dem Solarzellensystem 7 zugeführt. Dabei werden die von den Aufbewahrungsrollen 9 bzw. 9a abgezogenen Materialbahnen jeweils einer Heizstation 14 bzw. 14a zugeführt, in welcher die Einkapselungsmateria- len 1, 1' zumindest auf die Erweichungstemperatur der Siegelschicht 6, 6' erwärmt werden. Dadurch ist die Ausbildung eines Verbundes zwischen den Schichten 1, 1' einerseits sowie dem Solarzellensystem 7 andererseits im Walzenspalt der Kalanderstation 15 gewährleistet. Um das Aushärten dieses Verbundes und das gänzliche Vernetzen der in den Einkapselungsmaterialien eingesetzten Polymere zu erzielen, wird der Vorverbund einer Heizstation 16 zugeführt. Der Verbund 17 für einen photovoltischen Modul kann auf der Aufbewahrungsrolle 9b gelagert und von dieser entsprechend abgezogen werden.In this case, for example, the solar cell system 7, consisting of flexible solar cell types, is applied to the encapsulation material 1 '. From the opposite storage roll 9, a further encapsulating material layer 1 is removed and fed to the solar cell system 7. The material webs drawn off from the storage rolls 9 and 9a are each fed to a heating station 14 or 14a in which the encapsulation materials 1, 1 'are heated at least to the softening temperature of the sealing layer 6, 6'. This ensures the formation of a bond between the layers 1, 1 'on the one hand and the solar cell system 7 on the other hand in the nip of the calendering station 15. In order to achieve the curing of this composite and the complete crosslinking of the polymers used in the encapsulating materials, the pre-bond is fed to a heating station 16. The composite 17 for a photovoltaic module can be stored on the storage roll 9b and deducted accordingly.
Durch das erfindungsgemäße Beschichtungsverfahren können in einem photovoltaischen Modul 18, dessen Schichtaufbau in Fig. 1 gezeigt wird, relativ dünne Materiallagen, insbesondere was die witterungsbeständige Schicht 2, 2' anbelangt, erzielt werden.As a result of the coating method according to the invention, in a photovoltaic module 18, the layer structure of which is shown in FIG. 1, relatively thin layers of material, in particular as regards the weather-resistant layer 2, 2 ', can be achieved.
Dies hat den Vorteil, dass bei Entsorgung der photovoltaischen Module der Anteil an fluorhältigen Polymeren im Vergleich zu han- delsüblichen Modulaufbauten reduziert werden kann.This has the advantage that, when disposing of the photovoltaic modules, the proportion of fluorine-containing polymers can be reduced in comparison with commercial module structures.
Weiters ist es im Rahmen des erfindungsgemäßen Verfahrens möglich, nicht nur einen chemisch einheitlichen Polymerfilm für die Beschichtung 2, 2' zu erzeugen, sondern auch eine Mischung aus unterschiedlichen Polymerrohstoffen in variierenden Verhältnissen bereitzustellen. Wie aus dem Stand der Technik bekannt, war der Einsatz von Polymerfolien im wesentlichen auf einen Polymertypus beschränkt. Gemäß Erfindung kann jedoch eine Mischung für die witterungsbeständige Schicht 2, 2' bereitgestellt werden, bei welcher durch Auswahl und Anteil der eingesetzten Polymerrohstoffe die physikalischen und/oder chemischen Eigenschaften der endgefertigtenFurthermore, it is possible in the context of the method according to the invention not only to produce a chemically uniform polymer film for the coating 2, 2 ', but also to provide a mixture of different polymer raw materials in varying ratios. As known in the art, the use of polymeric films was essentially limited to one polymer type. According to the invention, however, it is possible to provide a mixture for the weather-resistant layer 2, 2 ', in which the physical and / or chemical properties of the finished product are selected and proportion of the polymer raw materials used
Beschichtung 2, 2' beliebig modifiziert und optimiert werden können.Coating 2, 2 'can be modified and optimized as desired.
Unabhängig davon ist die Herstellung verfahrensökonomisch, da die Dicke der witterungsbeständigen Schicht 2, Z' reduziert und damit der Anteil an relativ kostenaufwendigen Fluorpolymeren verrin- gert werden kann. Das Verfahren lässt sich in-situ durchführen, was die Verfahrensführung wesentlich erleichtert. Durch Auswahl der eingesetzten Polymere und Lösungsmittel können Temperaturbereiche, welche vorteilhafterweise zwischen 80 und 180" C liegen, eingestellt werden, sodass auch eine energiesparende Verfahrensführung ermög- licht wird.Irrespective of this, the production is economical in terms of process, since the thickness of the weather-resistant layer 2, Z 'can be reduced and thus the proportion of relatively expensive fluoropolymers can be reduced. The process can be carried out in-situ, which the process management much easier. By selecting the polymers and solvents used, temperature ranges which are advantageously between 80 and 180 ° C. can be set so that energy-saving process control is also made possible.
Des Weiteren kann, je nach Anwendungszweck, die Dicke der witterungsbeständigen Schicht 2, 2' eingestellt werden. Durch Einstellen dieser Schichtdicke sind eine Reihe von Anwendungsmöglich- keiten des photovoltaischen Moduls unter Verwendung der erfindungs- gemäß hergestellten Einkapselungsmaterialien möglich, welche von Kleinenergieanlagen für Notrufsäulen oder Wohnmobile bis hin zu großflächigen Dach- und Fassadenanlagen sowie auch Großanlagen und Solarkraftwerken reichen. Furthermore, depending on the purpose of use, the thickness of the weather-resistant layer 2, 2 'can be adjusted. By adjusting this layer thickness, a number of possible uses of the photovoltaic module using the encapsulation materials produced according to the invention are possible, ranging from small-scale power systems for emergency call or mobile homes to large-scale roof and façade systems as well as large-scale systems and solar power plants.

Claims

Ansprüche : Claims :
1. Verfahren zum Herstellen witterungsbeständiger Laminate (1, 1') für die Einkapselung von Solarzellensystemen (7), dadurch ge- kennzeichnet, dass auf ein Tragermaterial (4, 4') zumindest eine witterungsbeständige Kunststoffschient (2, 2') aufgetragen wird.1. A method for producing weather-resistant laminates (1, 1 ') for the encapsulation of solar cell systems (7), characterized in that on a carrier material (4, 4') at least one weather-resistant plastic splint (2, 2 ') is applied.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die witterungsbeständigen Kunststoffe aus der Gruppe selektiv losliche Fluorpolymere bzw. Fluorcopolymere, Acrylate, Polyurethane, Silikone sowie Mischungen daraus ausgewählt werden.2. The method according to claim 1, characterized in that the weather-resistant plastics from the group selectively soluble fluoropolymers or fluoropolymers, acrylates, polyurethanes, silicones and mixtures thereof are selected.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die witterungsbeständigen Kunststoffe aus einer Losung und/oder einer Dispersion auf das Tragermaterial (4, 4') aufgetragen werden.3. The method according to claim 1 or 2, characterized in that the weather-resistant plastics from a solution and / or a dispersion on the carrier material (4, 4 ') are applied.
4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass die Losung oder Dispersion Farbstoffe enthalt.4. The method according to claim 3, characterized in that the solution or dispersion contains dyes.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Verfahrenstemperatur in einem Bereich zwischen 80 und 180 "C eingestellt wird.5. The method according to any one of claims 1 to 4, characterized in that the process temperature is set in a range between 80 and 180 "C.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekenn- zeichnet, dass die witterungsbeständigen Kunststoffe in einer6. The method according to any one of claims 1 to 5, characterized in that the weather-resistant plastics in one
Schichtdicke von 5 bis 50 um aufgetragen werden.Layer thickness of 5 to 50 microns are applied.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die witterungsbeständige Schicht (2, 2') im sichtbaren Lichtwellenbereich und im nahen UV-Wellenlangenbereich für Lichtstrahlen durchlässig ist.7. The method according to any one of claims 1 to 6, characterized in that the weather-resistant layer (2, 2 ') in the visible light wave range and in the near UV wavelength range is transparent to light rays.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Tragermaterial (4, 4') aus der Gruppe Polyethy- lenterephtalat (PET), Polyethylennaphtenat (PEN), Ethylentetrafluo- rethylencopolymer (ETFE) sowie Co-Extrutade daraus ausgewählt wird. 8. The method according to any one of claims 1 to 7, characterized in that the carrier material (4, 4 ') from the group polyethylene terephthalate (PET), polyethylene naphthenate (PEN), ethylene tetrafluoroethylene ethylene copolymer (ETFE) as well as co-Extrutade thereof selected becomes.
9. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Tragermaterial (4, 4') eine Aluminiumfolie ist. 9. The method according to any one of claims 1 to 7, characterized in that the carrier material (4, 4 ') is an aluminum foil.
10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass das Tragermaterial (4, 4') vor dem Beschichten physikalisch und/oder chemisch vorbehandelt wird. 10. The method according to any one of claims 1 to 9, characterized in that the carrier material (4, 4 ') is pretreated physically and / or chemically before coating.
11. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, dass auf das Tragermaterial (4, 4') eine aus der Dampfphase abgeschiedene anorganische Oxidschicht aufgebracht wird. 11. The method according to any one of claims 1 to 10, characterized in that on the carrier material (4, 4 ') deposited from the vapor phase inorganic oxide layer is applied.
12. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, dass auf das Tragermaterial (4, 41) ein Kleber aufgetragen wird. 12. The method according to any one of claims 1 to 10, characterized in that on the carrier material (4, 4 1 ) an adhesive is applied.
13. Verfahren nach Anspruch 12, dadurch gekennzeichnet, dass als Kleber ein Polyurethan- oder Polyesterkleber verwendet wird.13. The method according to claim 12, characterized in that a polyurethane or polyester adhesive is used as the adhesive.
14. Verfahren nach einem der Ansprüche 1 bis 13, dadurch gekennzeichnet, dass auf die unbeschichtete Seite des Trägermaterials (4, 4') eine Adhäsionsschicht (5, 5') aufgebracht wird.14. The method according to any one of claims 1 to 13, characterized in that on the uncoated side of the carrier material (4, 4 ') an adhesion layer (5, 5') is applied.
15. Verfahren nach Anspruch 14, dadurch gekennzeichnet, dass die Adhäsionsschicht (5, 5') durch ein Primersystem, eine oberflächenbehandelte Fluorpolymer / Fluorcopolymerschicht, eine Polyurethanoder Polyacrylatschicht bereitgestellt wird. A method according to claim 14, characterized in that the adhesion layer (5, 5 ') is provided by a primer system, a surface-treated fluoropolymer / fluorocopolymer layer, a polyurethane or polyacrylate layer.
16. Verfahren nach Anspruch 14 oder 15, dadurch gekennzeichnet, dass angrenzend an die Adhäsionsschicht (5, 51) eine Siegelschicht (6, 6'} angebracht wird.16. The method according to claim 14 or 15, characterized in that adjacent to the adhesion layer (5, 5 1 ) a sealing layer (6, 6 '} is attached.
17. Verfahren nach Anspruch 16, dadurch gekennzeichnet, dass die Siegelschicht (6, 6') aus der Gruppe Ethylenvinylacetat (EVA), Polyvinylbutyral (PVB), Ionomere, Polymethylmethacrylat (PMMA), Polyurethan, Polyester oder Hot MeIt Polymere gebildet wird.17. The method according to claim 16, characterized in that the sealing layer (6, 6 ') from the group ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), ionomers, polymethyl methacrylate (PMMA), polyurethane, polyester or hot melt polymers is formed.
18. Verwendung zumindest zweier nach einein der Ansprüche 1 bis 17 hergestellten Laminate (1, 1') zum Herstellen eines photovoltaischen Moduls (17), wobei an einem der Laminate (1, 1') das Solarzellensys- tem (7) angebracht wird.18. Use of at least two laminates (1, 1 ') produced according to one of claims 1 to 17 for producing a photovoltaic module (17), wherein the solar cell system (7) is attached to one of the laminates (1, 1').
19. Verwendung nach Anspruch 18, dadurch gekennzeichnet, dass die Herstellung des photovoltaischen Moduls (18) durch ein kontinuierliches Laminierverfahren erfolgt, in welchem ein Vorverbund (17) für den photovoltischen Modul (18) hergestellt wird. 19. Use according to claim 18, characterized in that the production of the photovoltaic module (18) by a continuous lamination process, in which a Vorverbund (17) for the photovoltaic module (18) is produced.
20. Verwendung nach Anspruch 19, dadurch gekennzeichnet, dass für die Herstellung des Vorverbundes (17) ein flexibler Solarzellentyp verwendet wird.20. Use according to claim 19, characterized in that a flexible solar cell type is used for the production of the pre-bond (17).
21. Verwendung nach Anspruch 18, dadurch gekennzeichnet, dass die Herstellung des photovoltaischen Moduls (17) durch ein diskontinu- ierlisches Verfahren erfolgt.21. Use according to claim 18, characterized in that the production of the photovoltaic module (17) takes place by a discontinuous method.
22. Verwendung nach einem der Ansprüche 18 bis 21, dadurch gekennzeichnet, dass als Solarzellensystem (7) eines aus Siliziumsolarzellen eingesetzt wird.22. Use according to any one of claims 18 to 21, characterized in that as solar cell system (7) one of silicon solar cells is used.
23. Verwendung einer nach Anspruch 3 hergestellten Dispersion zum Reparieren von beschädigten Rückseiten eines photovoltaischen Moduls . 23. Use of a dispersion prepared according to claim 3 for repairing damaged backs of a photovoltaic module.
EP06760782A 2005-07-21 2006-07-10 Method for producing weather-resistant laminates for encapsulating solar cell systems Withdrawn EP1904300A1 (en)

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AT0123005A AT502234B1 (en) 2005-07-21 2005-07-21 PROCESS FOR PREPARING WEATHER-RESISTANT LAMINATES FOR THE INCLUSION OF SOLAR CELL SYSTEMS
PCT/AT2006/000295 WO2007009140A1 (en) 2005-07-21 2006-07-10 Method for producing weather-resistant laminates for encapsulating solar cell systems

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EP1904300A1 true EP1904300A1 (en) 2008-04-02

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AU2006272417A1 (en) 2007-01-25
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PE20070474A1 (en) 2007-06-17

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