CN107362962A - Base material with wavelength convert function, its forming method and its application - Google Patents
Base material with wavelength convert function, its forming method and its application Download PDFInfo
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- CN107362962A CN107362962A CN201610311228.1A CN201610311228A CN107362962A CN 107362962 A CN107362962 A CN 107362962A CN 201610311228 A CN201610311228 A CN 201610311228A CN 107362962 A CN107362962 A CN 107362962A
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Abstract
Description
技术领域technical field
本发明属于太阳能转换用器件设计技术领域，具体涉及一种具有波长转换功能的基材、其成型方法及其应用。The invention belongs to the technical field of device design for solar energy conversion, and in particular relates to a base material with wavelength conversion function, its forming method and its application.
背景技术Background technique
太阳能电池是一种将太阳能直接转换为电能的半导体器件，是当前一种比较清洁的新能源形式。该类器件能产生电的主要原理是：通过太阳光谱中固定波长范围内的光照射在太阳能电池上，并被电池器件的界面层吸收激发形成电子-空穴对，利用半导体器件的内建电场将电子和空穴分离而得到电流。A solar cell is a semiconductor device that directly converts solar energy into electrical energy, and is currently a relatively clean form of new energy. The main principle that this type of device can generate electricity is: the light in the fixed wavelength range in the solar spectrum is irradiated on the solar cell, and is absorbed and excited by the interface layer of the cell device to form electron-hole pairs, and the built-in electric field of the semiconductor device is used. Electrons and holes are separated to obtain electric current.
图1是在大气质量为1.5的标准条件下测得的太阳能光谱，从图中我们可以看出，标准的太阳光谱中大部分能量是分布在400-800nm的可见光范围，还有一部分分布在800-2400nm的红外波段，这些波段的能量几乎都能对发电起到作用，但是在280-400nm波段的紫外光却无法用来产生电能，反而还会对太阳能电池中的高分子材料部分产生破环并使其发生老化现象(例如：太阳能电池中的PET、EVA、粘合剂等)，影响了电池的使用寿命和稳定性。Figure 1 is the solar spectrum measured under the standard condition of air mass of 1.5. We can see from the figure that most of the energy in the standard solar spectrum is distributed in the visible light range of 400-800nm, and some of it is distributed in the 800nm In the infrared band of -2400nm, the energy of these bands can almost play a role in power generation, but the ultraviolet light in the 280-400nm band cannot be used to generate electricity, but it will also damage the polymer materials in the solar cell. And make it aging (for example: PET, EVA, adhesives, etc. in solar cells), which affects the service life and stability of the battery.
另外，针对有些类别的太阳能电池(例如OPV电池)，紫外光还会对电池的核心发电部分产生致命性损坏，直接导致电池失效。In addition, for some types of solar cells (such as OPV cells), ultraviolet light will also cause fatal damage to the core power generation part of the cell, directly causing the cell to fail.
有些太阳能电池设计时会直接在组成发电器件的材料中加入紫外吸收剂，将紫外光直接吸收来减少紫外光对电池的影响，这样相当于是将紫外光波段的能量直接损耗了，这对于太阳能电池发电效率的提高是不利的。Some solar cells are designed to directly add ultraviolet absorbers to the materials that make up the power generation device, and absorb ultraviolet light directly to reduce the impact of ultraviolet light on the battery. This is equivalent to directly losing the energy in the ultraviolet band, which is for solar cells An increase in power generation efficiency is disadvantageous.
目前，现有技术中并没有合理的解决方案以实现有效利用紫外光，提高太阳能的发电效率的目的。At present, there is no reasonable solution in the prior art to achieve the purpose of effectively utilizing ultraviolet light and improving the power generation efficiency of solar energy.
因此，鉴于以上问题，有必要提出一种新颖的基材，可以实现对紫外光合理的转化直接应用在光伏发电器件中，从而将紫外光的能量充分利用，间接提高了光伏器件的发电效率。Therefore, in view of the above problems, it is necessary to propose a novel substrate that can achieve a reasonable conversion of ultraviolet light and be directly applied to photovoltaic power generation devices, so as to fully utilize the energy of ultraviolet light and indirectly improve the power generation efficiency of photovoltaic devices.
发明内容Contents of the invention
有鉴于此，本发明提供了一种具有波长转换功能的基材及其成型方法，该基材具有较好的波长转换功能，且具有在户外长时间使用而不会使高分子材料发生老化的特点，能很好地将紫外波段的太阳光转换为可见光被光伏发电器件所吸收而转换为电能，能显著提高光伏器件的发电效率，是一种新颖的功能性基材。In view of this, the present invention provides a substrate with a wavelength conversion function and a molding method thereof. The substrate has a good wavelength conversion function and has the ability to be used outdoors for a long time without aging the polymer material. It is a novel functional substrate that can well convert sunlight in the ultraviolet band into visible light, which is absorbed by photovoltaic power generation devices and converted into electrical energy, and can significantly improve the power generation efficiency of photovoltaic devices.
根据本发明的目的提出的一种具有波长转换功能的基材，所述基材包括：A kind of base material with wavelength conversion function proposed according to the object of the present invention, said base material comprises:
基材层；substrate layer;
前处理层，设置于所述基材层的至少一表面上，用以实现波长转换；A pretreatment layer, disposed on at least one surface of the base material layer, for realizing wavelength conversion;
所述前处理层通过在所述基材层上涂覆胶水形成，涂覆的胶水为丙烯酸类树脂与波长转换剂的混合物；The pretreatment layer is formed by coating glue on the substrate layer, and the coated glue is a mixture of acrylic resin and wavelength conversion agent;
所述波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。The wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm.
优选的，所述波长转换剂是一种掺杂稀土的无机氧化物粒子，所述波长转换剂的成分结构式为Sr5(PO4)3Cl:Eu2+或YPO4:Tb或LaPO4:Tm。Preferably, the wavelength conversion agent is an inorganic oxide particle doped with rare earth, and the structural formula of the wavelength conversion agent is Sr 5 (PO 4 ) 3 Cl:Eu 2+ or YPO 4 :Tb or LaPO 4 : Tm.
优选的，所述波长转换剂均匀分散于所述丙烯酸类树脂中，所述波长转换剂的颗粒粒径范围为50nm-10μm。Preferably, the wavelength conversion agent is uniformly dispersed in the acrylic resin, and the particle size of the wavelength conversion agent ranges from 50 nm to 10 μm.
优选的，所述波长转换剂所占丙烯酸类树脂胶水的质量配比为0.3％-3％。Preferably, the mass ratio of the wavelength conversion agent to the acrylic resin glue is 0.3%-3%.
优选的，所述前处理层厚度为75nm-90nm。Preferably, the thickness of the pretreatment layer is 75nm-90nm.
优选的，所述基材层为25μm-300μm厚度的聚酯薄膜基材。Preferably, the substrate layer is a polyester film substrate with a thickness of 25 μm-300 μm.
优选的，所述基材层的光学透过率在90％以上。Preferably, the optical transmittance of the substrate layer is above 90%.
优选的，所述前处理层的远离所述基材层的表面上还涂覆有一层硬化层。Preferably, a hardened layer is further coated on the surface of the pretreatment layer away from the substrate layer.
优选的，所述硬化层厚度为3μm-5μm。Preferably, the thickness of the hardened layer is 3 μm-5 μm.
优选的，所述硬化层涂料为聚氨酯涂料或无机纳米陶瓷涂料或辐射固化涂料。Preferably, the hardened layer coating is polyurethane coating or inorganic nano-ceramic coating or radiation curing coating.
一种具有波长转换功能的基材的成型方法，具体步骤如下：A method for forming a base material with a wavelength conversion function, the specific steps are as follows:
S1：制作基材层；S1: making the substrate layer;
S2：在所述基材层的至少一表面上通过涂布的方法涂覆丙烯酸类树脂与波长转换剂的混合物的溶液，然后去除溶剂来形成前处理层，S2: coating a solution of a mixture of an acrylic resin and a wavelength conversion agent on at least one surface of the substrate layer by coating, and then removing the solvent to form a pretreatment layer,
其中，所述波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。Wherein, the wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm.
优选的，所述基材层为PET或者PEN基材，步骤S1进一步包括对所述基材层进行表面处理，所述表面处理为放电处理、化学预处理或火焰预处理。Preferably, the substrate layer is a PET or PEN substrate, and step S1 further includes performing surface treatment on the substrate layer, and the surface treatment is discharge treatment, chemical pretreatment or flame pretreatment.
优选的，所述前处理层的远离所述基材层的表面上还涂覆有一层硬化层，通过涂布方法涂覆至少一种可交联单体的溶液，然后通过暴露于可见光、紫外线和/或电子束辐射进行交联来在所述前处理层上形成所述硬化层。Preferably, the surface of the pretreatment layer away from the substrate layer is also coated with a layer of hardening layer, and the solution of at least one crosslinkable monomer is coated by a coating method, and then exposed to visible light, ultraviolet light and/or electron beam irradiation to form the hardened layer on the pretreatment layer.
一种封装结构，包括基材，所述基材为具有波长转换功能的基材或者由具有波长转换功能的基材的成型方法所制成的基材。An encapsulation structure includes a base material, and the base material is a base material with a wavelength conversion function or a base material made by a molding method of a base material with a wavelength conversion function.
一种薄膜太阳能电池，包括封装结构。A thin-film solar battery includes an encapsulation structure.
与现有技术相比，本发明公开的具有波长转换功能的基材、其成型方法及其应用的优点是：Compared with the prior art, the advantages of the substrate with wavelength conversion function disclosed by the present invention, its forming method and its application are:
该基材具有较好的波长转换功能，且具有在户外长时间使用而不会使高分子材料发生老化的特点，能很好地将紫外波段的太阳光转换为可见光中的蓝光部分，而蓝光能被大部分的光伏发电器件所吸收而转换为电能，能显著提高光伏器件的发电效率，是一种新颖的功能性基材。The substrate has a good wavelength conversion function, and has the characteristics of being used outdoors for a long time without aging the polymer material. It can well convert sunlight in the ultraviolet band into the blue part of visible light, while blue light It can be absorbed by most photovoltaic power generation devices and converted into electrical energy, which can significantly improve the power generation efficiency of photovoltaic devices, and is a novel functional substrate.
通过在带有前处理层的基材层的上下侧涂覆有一层硬化层，有效提高基材的表面硬度与机械强度，避免基材表面划伤与磨损，提高基材质量。By coating the upper and lower sides of the substrate layer with the pretreatment layer with a hardened layer, the surface hardness and mechanical strength of the substrate can be effectively improved, scratches and wear on the substrate surface can be avoided, and the quality of the substrate can be improved.
附图说明Description of drawings
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only These are some embodiments of the present invention. Those skilled in the art can also obtain other drawings based on these drawings without creative work.
图1为在大气质量为1.5的标准条件下测得的太阳能光谱图。Figure 1 is a solar spectrum measured under the standard condition that the air quality is 1.5.
图2为本发明公开的基材的结构示意图。Fig. 2 is a schematic structural view of the substrate disclosed in the present invention.
图中的数字或字母所代表的相应部件的名称：The names of the corresponding parts represented by numbers or letters in the figure:
1、基材层2、前处理层3、硬化层1. Substrate layer 2. Pretreatment layer 3. Hardened layer
具体实施方式detailed description
紫外光无法产生电能，反而还会对太阳能电池中的高分子材料部分产生破环并使其发生老化现象，影响了电池的使用寿命和稳定性。有些太阳能电池设计时会直接在组成发电器件的材料中加入紫外吸收剂，将紫外光直接吸收来减少紫外光对电池的影响，如：光能电池及其红光转换层(申请号：200710152316.2)，该申请中通过设置转换层以吸收太阳光谱紫外线、紫蓝、浅蓝、黄-绿部分，并转换为红光、暗红光及近红外线的次能带辐射，其主要作用是吸收紫外，提高转化效率，并没有很好的转化利用紫外光。这样相当于是将紫外光波段的能量直接损耗了，这对于太阳能电池发电效率的提高是不利的。Ultraviolet light cannot generate electricity, but it will also damage the polymer material in the solar cell and cause it to age, which affects the service life and stability of the battery. When some solar cells are designed, UV absorbers are directly added to the materials that make up the power generation device, and the UV light is directly absorbed to reduce the impact of UV light on the battery, such as: photovoltaic cells and their red light conversion layers (application number: 200710152316.2) In this application, the conversion layer is set to absorb the ultraviolet, purple blue, light blue, yellow-green part of the solar spectrum, and convert it into red light, dark red light and near-infrared sub-band radiation. Its main function is to absorb ultraviolet light, Improve the conversion efficiency, and do not use ultraviolet light well. This is equivalent to directly losing the energy in the ultraviolet band, which is unfavorable for the improvement of the power generation efficiency of the solar cell.
又如：一种具有波长转换材料的密封材料板以及使用其的太阳能电池(专利号201110021649.8)，其通过在密封材料中混入荧光体以提高光电转换效率，荧光体在300nm以上处存在激发带，而紫外线波长范围在10nm-400nm，该材料板并不能实现很好的转换紫外光的目的，光能利用率差。Another example: a sealing material plate with a wavelength conversion material and a solar cell using it (Patent No. 201110021649.8), which improves the photoelectric conversion efficiency by mixing phosphors into the sealing material, and the phosphors have excitation bands above 300nm. However, the ultraviolet wavelength ranges from 10nm to 400nm, and the material plate cannot achieve the purpose of converting ultraviolet light very well, and the utilization rate of light energy is poor.
目前现有技术中并没有合理方式以实现有效利用紫外光，提高太阳能的发电效率。At present, there is no reasonable way in the prior art to realize the effective utilization of ultraviolet light and improve the power generation efficiency of solar energy.
本发明针对现有技术中的不足，提供了一种具有波长转换功能的基材、其成型方法及其应用，该基材具有较好的波长转换功能，且具有在户外长时间使用而不会使高分子材料发生老化的特点，能很好地将紫外波段的太阳光转换为可见光被光伏发电器件所吸收而转换为电能，能显著提高光伏器件的发电效率，是一种新颖的功能性基材。Aiming at the deficiencies in the prior art, the present invention provides a base material with wavelength conversion function, its forming method and its application. The base material has better wavelength conversion function and can be used outdoors for a long time without The characteristics of aging polymer materials can well convert sunlight in the ultraviolet band into visible light, which is absorbed by photovoltaic power generation devices and converted into electrical energy, which can significantly improve the power generation efficiency of photovoltaic devices. It is a novel functional basis. material.
根据本发明的目的提出的一种具有波长转换功能的基材，用以将紫外光转换为可见光，所述基材包括：A kind of base material with wavelength conversion function proposed according to the object of the present invention, in order to convert ultraviolet light into visible light, said base material comprises:
基材层；substrate layer;
前处理层，设置于所述基材层的至少一表面上，用以实现波长转换；A pretreatment layer, disposed on at least one surface of the base material layer, for realizing wavelength conversion;
所述前处理层通过在所述基材层上涂覆胶水形成，涂覆的胶水为丙烯酸类树脂与波长转换剂的混合物；The pretreatment layer is formed by coating glue on the substrate layer, and the coated glue is a mixture of acrylic resin and wavelength conversion agent;
所述波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。The wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm.
优选的，所述波长转换剂是一种掺杂稀土的无机氧化物粒子，所述波长转换剂的成分结构式为Sr5(PO4)3Cl:Eu2+或YPO4:Tb或LaPO4:Tm。Preferably, the wavelength conversion agent is an inorganic oxide particle doped with rare earth, and the structural formula of the wavelength conversion agent is Sr 5 (PO 4 ) 3 Cl:Eu 2+ or YPO 4 :Tb or LaPO 4 : Tm.
优选的，所述波长转换剂均匀分散于所述丙烯酸类树脂中，所述波长转换剂的颗粒粒径范围为50nm-10μm。Preferably, the wavelength conversion agent is uniformly dispersed in the acrylic resin, and the particle size of the wavelength conversion agent ranges from 50 nm to 10 μm.
优选的，所述波长转换剂所占丙烯酸类树脂胶水的质量配比为0.3％-3％。Preferably, the mass ratio of the wavelength conversion agent to the acrylic resin glue is 0.3%-3%.
优选的，所述前处理层厚度为75nm-90nm。Preferably, the thickness of the pretreatment layer is 75nm-90nm.
优选的，所述基材层为25μm-300μm厚度的聚酯薄膜基材。Preferably, the substrate layer is a polyester film substrate with a thickness of 25 μm-300 μm.
优选的，所述基材层的光学透过率在90％以上。Preferably, the optical transmittance of the substrate layer is above 90%.
优选的，所述前处理层的表面上还涂覆有一层硬化层。Preferably, a hardened layer is also coated on the surface of the pretreatment layer.
优选的，所述硬化层厚度为3μm-5μm。Preferably, the thickness of the hardened layer is 3 μm-5 μm.
优选的，所述硬化层涂料为聚氨酯涂料或无机纳米陶瓷涂料或辐射固化涂料。Preferably, the hardened layer coating is polyurethane coating or inorganic nano-ceramic coating or radiation curing coating.
一种具有波长转换功能的基材的成型方法，具体步骤如下：A method for forming a base material with a wavelength conversion function, the specific steps are as follows:
S1：制作基材层；S1: making the substrate layer;
S2：在所述基材层的至少一表面上通过涂布的方法涂覆丙烯酸类树脂与波长转换剂的混合物的溶液，然后去除溶剂来形成前处理层，S2: coating a solution of a mixture of an acrylic resin and a wavelength conversion agent on at least one surface of the substrate layer by coating, and then removing the solvent to form a pretreatment layer,
其中，所述波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。Wherein, the wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm.
优选的，所述基材层为PET或者PEN基材，步骤S1进一步包括对所述基材层进行表面处理，所述表面处理为放电处理、化学预处理或火焰预处理。Preferably, the substrate layer is a PET or PEN substrate, and step S1 further includes performing surface treatment on the substrate layer, and the surface treatment is discharge treatment, chemical pretreatment or flame pretreatment.
优选的，所述前处理层的表面上还涂覆有一层硬化层，通过涂布方法涂覆至少一种可交联单体的溶液，然后通过暴露于可见光、紫外线和/或电子束辐射进行交联来在所述前处理层上形成所述硬化层。Preferably, a layer of hardening layer is also coated on the surface of the pretreatment layer, and the solution of at least one crosslinkable monomer is coated by a coating method, and then is exposed to visible light, ultraviolet light and/or electron beam radiation. crosslinking to form the hardened layer on the pretreatment layer.
一种封装结构，包括基材，所述基材为具有波长转换功能的基材或者由具有波长转换功能的基材的成型方法所制成的基材。An encapsulation structure includes a base material, and the base material is a base material with a wavelength conversion function or a base material made by a molding method of a base material with a wavelength conversion function.
一种薄膜太阳能电池，包括封装结构。A thin-film solar battery includes an encapsulation structure.
下面将通过具体实施方式对本发明的技术方案进行清楚、完整地描述。显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The technical solutions of the present invention will be clearly and completely described below through specific embodiments. Apparently, the described embodiments are only some of the embodiments of the present invention, but not all of them. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without creative efforts fall within the protection scope of the present invention.
请参见图2，如图所示，一种具有波长转换功能的基材，用以将紫外光转换为可见光，该基材包括基材层1，基材层1的上下两面分别涂覆胶水形成一层前处理层2。其中基材层选用25μm-300μm厚度的经过表面处理的聚酯薄膜基材。可为PET(聚对笨二甲酸)或PEN(聚萘二甲酸乙二醇酯)基材。其中选用的基材层的光学透过率要保证在90％以上，以满足使用需要。基材层的厚度一般可选用50μm、100μm、150μm、200μm、250μm等多个尺寸，具体厚度根据使用需要而定，具体不做限制。Please refer to Figure 2, as shown in the figure, a substrate with a wavelength conversion function is used to convert ultraviolet light into visible light. The substrate includes a substrate layer 1, and the upper and lower sides of the substrate layer 1 are coated with glue to form A pre-processing layer 2. Wherein the substrate layer is a surface-treated polyester film substrate with a thickness of 25 μm-300 μm. It can be PET (polyethylene terephthalate) or PEN (polyethylene naphthalate) substrate. The optical transmittance of the selected substrate layer should be guaranteed to be above 90%, so as to meet the needs of use. The thickness of the substrate layer can generally be selected from multiple sizes such as 50 μm, 100 μm, 150 μm, 200 μm, 250 μm, etc. The specific thickness is determined according to the needs of use, and there is no specific limitation.
基材层1的表面可以经过处理以提高对耐候层和/或前处理层的粘附力。可用的表面处理包括在存在适合的反应性或非反应性大气环境的情况下进行的放电(如等离子体、辉光放电、电晕放电、电介质阻隔放电或大气压放电)、化学预处理、或火焰预处理等方式。The surface of the substrate layer 1 may be treated to improve the adhesion to the weather-resistant layer and/or the pre-treatment layer. Available surface treatments include discharge (such as plasma, glow discharge, corona discharge, dielectric barrier discharge, or atmospheric pressure discharge), chemical pretreatment, or flame in the presence of a suitable reactive or non-reactive atmosphere preprocessing etc.
其中，前处理层厚度范围为75nm-90nm。优选为80nm，前处理层的作用是填充PET表面的起伏及空隙，使得基材层表面平整光滑。Wherein, the thickness range of the pretreatment layer is 75nm-90nm. The thickness is preferably 80nm. The function of the pre-treatment layer is to fill the ups and downs and gaps on the PET surface, so that the surface of the substrate layer is smooth and smooth.
涂覆的胶水为丙烯酸类树脂与波长转换剂的混合物，可以用常规涂布方法如辊涂(例如凹版辊涂)或喷涂(例如静电喷涂)来施加可用于形成所述前处理层的单体或低聚物，然后使用常规技术(例如热或真空)去除溶剂来形成所述前处理层2。The coating glue is a mixture of acrylic resin and wavelength conversion agent, and the monomers that can be used to form the pre-treatment layer can be applied by conventional coating methods such as roll coating (such as gravure roll coating) or spray coating (such as electrostatic spray coating) or oligomers, and then remove the solvent using conventional techniques (such as heat or vacuum) to form the pretreatment layer 2 .
波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。The wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm.
波长转换剂是一种掺杂稀土的无机氧化物粒子，波长转换剂的成分结构式为Sr5(PO4)3Cl:Eu2+或YPO4:Tb或LaPO4:Tm，是一种把太阳光中紫外光部分转化成蓝光或绿光或红光的荧光粉，该荧光粉激发波长在200～410nm。转化后的可见光能被大部分的光伏发电器件所吸收而转换为电能，能显著提高光伏器件的发电效率。The wavelength conversion agent is a kind of inorganic oxide particles doped with rare earth. The structural formula of the wavelength conversion agent is Sr 5 (PO 4 ) 3 Cl:Eu 2+ or YPO 4 :Tb or LaPO 4 :Tm. The ultraviolet light part in the light is converted into blue light, green light or red light phosphor, and the excitation wavelength of the phosphor is 200-410nm. The converted visible light energy is absorbed by most photovoltaic power generation devices and converted into electrical energy, which can significantly improve the power generation efficiency of photovoltaic devices.
制作时将波长转换剂均匀分散在丙烯酸类树脂中，其颗粒粒径范围保证在50nm-10μm之间，优选为1μm，波长转换剂与丙烯酸类树脂胶水的质量配比范围在0.3％-3％之间，优选配比为1％、2％。前处理层的厚度及波长转换剂的颗粒粒径范围及其质量配比对转化率起到决定性作用，具体数值可根据使用需要而定，在此不做限制。During production, the wavelength conversion agent is uniformly dispersed in the acrylic resin, and the particle size range is guaranteed to be between 50nm-10μm, preferably 1μm. The mass ratio of the wavelength conversion agent to the acrylic resin glue is in the range of 0.3%-3%. Between, the preferred ratio is 1%, 2%. The thickness of the pretreatment layer and the particle size range and mass ratio of the wavelength conversion agent play a decisive role in the conversion rate, and the specific values can be determined according to the needs of use, and are not limited here.
此外，带有前处理层的基材层的表面上还涂覆有一层硬化层3。硬化层3厚度一般为3μm-5μm，优选为4μm，具体厚度根据使用需要而定，在此不做限制。In addition, a layer of hardening layer 3 is also coated on the surface of the substrate layer with the pretreatment layer. The thickness of the hardened layer 3 is generally 3 μm-5 μm, preferably 4 μm, and the specific thickness is determined according to the needs of use, and is not limited here.
硬化层涂料为聚氨酯涂料或无机纳米陶瓷涂料或辐射固化涂料。硬化层3的作用除了跟前处理层一样使基材层表面平坦化外，还可以提高基材层的耐高温性能，增强基材的表面硬度和机械强度。The hardened layer coating is polyurethane coating or inorganic nano-ceramic coating or radiation curing coating. The function of the hardened layer 3 is not only to flatten the surface of the substrate layer like the pretreatment layer, but also to improve the high temperature resistance of the substrate layer, and to enhance the surface hardness and mechanical strength of the substrate.
可通过使用常规的涂覆方法如辊涂(例如凹版辊涂)、喷涂(例如静电喷涂)、淋幕式涂布、模具涂布等，涂覆至少一种可交联单体的溶液，然后通过暴露于可见光、紫外线和/或电子束辐射进行交联来在所述前处理层上形成所述硬化层。The solution of at least one crosslinkable monomer can be applied by using conventional coating methods such as roll coating (eg gravure coating), spray coating (eg electrostatic spray coating), curtain coating, die coating, etc., and then The hardened layer is formed on the pre-treatment layer by cross-linking by exposure to visible light, ultraviolet light, and/or electron beam radiation.
上述具有波长转换功能的基材的成型方法，具体步骤如下：The above-mentioned molding method of the base material with wavelength conversion function, the specific steps are as follows:
S1：选取一定厚度的经过表面处理的PET或者PEN基材作为基材层，基材层的表面经过处理以提高对耐候层和/或前处理层的粘附力；可用的表面处理包括在存在适合的反应性或非反应性大气环境的情况下进行的放电、化学预处理或火焰预处理；S1: Select a certain thickness of surface-treated PET or PEN substrate as the substrate layer. The surface of the substrate layer has been treated to improve the adhesion to the weather-resistant layer and/or pre-treatment layer; available surface treatments include electrical discharge, chemical pretreatment or flame pretreatment in the presence of suitable reactive or non-reactive atmospheres;
S2：在基材层的上下两面，通过涂布的方法各涂覆一层前处理层以填充基材层表面的起伏及空隙，使得基材层表面平整光滑，涂覆的胶水为丙烯酸类树脂和波长转换剂的混合物，通过涂布方法来施加可用于形成所述前处理层的单体或低聚物，然后去除溶剂来形成前处理层，波长转换剂将太阳光中紫外光部分转换为蓝光或绿光或红光，波长转换剂激发波长范围为200nm-410nm；S2: On the upper and lower sides of the substrate layer, apply a layer of pretreatment layer by coating method to fill the ups and downs and gaps on the surface of the substrate layer, so that the surface of the substrate layer is smooth and smooth, and the glue coated is acrylic resin A mixture of a wavelength conversion agent and a monomer or oligomer that can be used to form the pre-treatment layer is applied by a coating method, and then the solvent is removed to form a pre-treatment layer. The wavelength conversion agent converts part of the ultraviolet light in sunlight into Blue light or green light or red light, the excitation wavelength range of the wavelength conversion agent is 200nm-410nm;
S3：通过涂布的方法在带有前处理层的基材层上下两面各涂覆一层硬化层，以填充基材层表面的起伏及空隙，使得基材层表面平整光滑，同时提高基材层的耐高温性能，增强基材层的表面硬度和机械强度，通过涂布方法涂覆至少一种可交联单体的溶液，然后通过暴露于可见光、紫外线和/或电子束辐射进行交联来在所述前处理层上形成所述硬化层。S3: Coating a layer of hardened layer on the upper and lower sides of the substrate layer with pretreatment layer by coating method to fill the undulations and gaps on the surface of the substrate layer, so that the surface of the substrate layer is smooth and smooth, and at the same time improve the quality of the substrate. High temperature resistance of the layer, enhancing the surface hardness and mechanical strength of the substrate layer, applying a solution of at least one crosslinkable monomer by a coating method, and then crosslinking by exposure to visible light, ultraviolet light and/or electron beam radiation to form the hardened layer on the pretreatment layer.
下面将结合具体实施例和对比例进一步说明本申请提供的基材。The substrate provided by the present application will be further described below in conjunction with specific examples and comparative examples.
实施例1Example 1
选取50μm厚度的PET作为基材层，该基材层正反两面经过电化学预处理以提高表面附着力。PET with a thickness of 50 μm is selected as the substrate layer, and the front and back sides of the substrate layer are electrochemically pretreated to improve surface adhesion.
在基材层的上下两面通过涂布的方式涂覆上一层1μm胶水，涂覆的胶水为丙烯酸类树脂和波长转换剂的混合物，波长转换剂选取的是YPO4:Tb，其中颗粒粒径范围分布在80nm-100nm之间，与丙烯酸类树脂配比为1％。A layer of 1 μm glue is coated on the upper and lower sides of the substrate layer by coating. The coated glue is a mixture of acrylic resin and a wavelength conversion agent. The wavelength conversion agent is YPO4:Tb, and the particle size range Distributed between 80nm-100nm, and the ratio of acrylic resin is 1%.
实施例2Example 2
选取50μm厚度的PET作为基材层，该基材层正反两面经过电化学预处理以提高表面附着力。PET with a thickness of 50 μm is selected as the substrate layer, and the front and back sides of the substrate layer are electrochemically pretreated to improve surface adhesion.
在基材层的上下两面通过涂布的方式涂覆上一层1μm胶水，涂覆的胶水为丙烯酸类树脂和波长转换剂的混合物，波长转换剂选取的是YPO4:Tb，其中颗粒粒径范围分布在80nm-100nm之间，与丙烯酸类树脂配比为1％。A layer of 1 μm glue is coated on the upper and lower sides of the substrate layer by coating. The coated glue is a mixture of acrylic resin and a wavelength conversion agent. The wavelength conversion agent is YPO4:Tb, and the particle size range Distributed between 80nm-100nm, and the ratio of acrylic resin is 1%.
通过涂布的方法在带有前处理层的基材层上下两面各涂覆一层4μm的硬化层，硬化层材料为聚氨酯类树脂，并通过紫外光进行固化。A hardening layer of 4 μm is coated on the upper and lower sides of the substrate layer with the pretreatment layer by coating method. The material of the hardening layer is polyurethane resin, which is cured by ultraviolet light.
对比例1Comparative example 1
选取50μm厚度的PET作为基材层，该基材层正反两面经过电化学预处理以提高表面附着力。PET with a thickness of 50 μm is selected as the substrate layer, and the front and back sides of the substrate layer are electrochemically pretreated to improve surface adhesion.
在基材层的上下两面通过涂布的方式涂覆上一层1μm胶水，涂覆的胶水为丙烯酸类树脂，并进行紫外光进行固化。A layer of 1 μm glue is coated on the upper and lower sides of the substrate layer by coating, the coated glue is acrylic resin, and is cured by ultraviolet light.
通过涂布的方法在带有前处理层的基材层上下两面各涂覆一层4μm的硬化层，硬化层材料为聚氨酯类树脂，并通过紫外光进行固化。A hardening layer of 4 μm is coated on the upper and lower sides of the substrate layer with the pretreatment layer by coating method. The material of the hardening layer is polyurethane resin, which is cured by ultraviolet light.
测试结果如下表所示：The test results are shown in the table below:
将实施例1、2和对比例1制备得到的三种基材与下层发电器件单元进行贴合，并将贴合后的三种发电单元放置在太阳光模拟器中进行发电效率的测试。效率测试的条件为：测试温度为25℃，测试表面辐照度为1000W/m2，大气质量为AM1.5，测试得到的发电效率如下：The three substrates prepared in Examples 1, 2 and Comparative Example 1 were bonded to the lower-layer power generation device units, and the bonded three power generation units were placed in a solar simulator to test the power generation efficiency. The conditions of the efficiency test are: the test temperature is 25°C, the test surface irradiance is 1000W/m 2 , and the air quality is AM1.5. The power generation efficiency obtained from the test is as follows:
测试结果表明，采用本发明中的基材能显著提高光伏器件的发电效率。The test results show that the power generation efficiency of photovoltaic devices can be significantly improved by using the base material in the invention.
本发明公开了一种具有波长转换功能的基材、其成型方法及其应用，该基材包括基材层，基材层的上下两面分别涂覆胶水形成一层前处理层，涂覆的胶水为丙烯酸类树脂与波长转换剂的混合物，波长转换剂用于将波长范围为200nm-410nm的光转化成波长范围为450nm-700nm的光。该基材具有较好的波长转换功能，且具有在户外长时间使用而不会使高分子材料发生老化的特点，能很好地将紫外波段的太阳光转换为可见光中的蓝光部分，而蓝光能被大部分的光伏发电器件所吸收而转换为电能，能显著提高光伏器件的发电效率，是一种新颖的功能性基材。The invention discloses a base material with wavelength conversion function, its forming method and its application. The base material comprises a base material layer, the upper and lower sides of the base material layer are respectively coated with glue to form a pretreatment layer, and the coated glue It is a mixture of acrylic resin and a wavelength conversion agent, and the wavelength conversion agent is used to convert light with a wavelength range of 200nm-410nm into light with a wavelength range of 450nm-700nm. The substrate has a good wavelength conversion function, and has the characteristics of being used outdoors for a long time without aging the polymer material. It can well convert sunlight in the ultraviolet band into the blue part of visible light, while blue light It can be absorbed by most photovoltaic power generation devices and converted into electrical energy, which can significantly improve the power generation efficiency of photovoltaic devices, and is a novel functional substrate.
通过在带有前处理层的基材层的上下侧涂覆有一层硬化层，有效提高基材的表面硬度与机械强度，避免基材表面划伤与磨损，提高基材质量。By coating the upper and lower sides of the substrate layer with the pretreatment layer with a hardened layer, the surface hardness and mechanical strength of the substrate can be effectively improved, scratches and wear on the substrate surface can be avoided, and the quality of the substrate can be improved.
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention will not be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
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