Background technology
The polymer materials that U.S. 2001/0045229A1 patent points out to make up the electronic component module should possess several kinds of character: ⑴ to long-term exposure element protective effect of (for example: aqueous vapor and air) in external environment; ⑵ shock resistance; ⑶ have tackiness to electronic component and base material; ⑷ be prone to processing treatment, is prone to sealing; ⑸ good transparency is particularly to light or other electromagnetic radiation; ⑹ the set time that short, and the protection electronic component avoids setting up period owing to the polymkeric substance contraction produces mechanical stress; ⑺ high resistance, and the electric conductivity of few (if the words that have); ⑻ low-cost.Do not have these several kinds of performances of a kind of polymer materials all to behave oneself best, need the most important performance of balance usually.
Based on above-mentioned performance requriements, the EVA with acetic acid content 28% to 35% generally is used as the packaging adhesive film of photovoltaic module.For example, see WO95/22844,99/ 0497199/04971,99/05206 and 2004/055908.EVA has property: snappiness, shock-resistance, elasticity that ⑴ is good; ⑵ have optical transparence; ⑶ low temperature is around song property, tackiness; ⑷ environmental stress crack resistance, weathering resistance, erosion resistance; ⑸ thermally sealed property and electrical insulating property.The EVA resin need add UV light stabilizing agent, and during the solar cell lamination is handled, uses peroxide crosslinking, to improve thermotolerance and the creep resistant between about 80-90 ℃.But the EVA glued membrane is not a kind of very ideal photoelectric cell packaging adhesive film, and the EVA glued membrane is prone to the chemistry degraded and xanthochromia gradually under influence of ultraviolet light.This variable color meeting causes that power loss is greater than 30% after short 4 years in the exposure environment, and in addition, the EVA resin also absorbs steam and decomposed.Because absorbing the UV radiation, the C=O key in the EVA molecular structure generates chromophoric group with solidifying residual cross-linker in the system of back.This packaging adhesive film intercepts the UV wavelength of 360nm.Photoelectricity module efficient is based on photoelectric cell efficient and decides through the sunlight wavelength of encapsulants.The most basically one of limiting for solar battery efficiency is that it partly leads the material energy gap, even electronics is excited to energy required in the movable conduction band from the base price band.The photon that has than energy gap energy still less is not absorbed, and the photon with energy higher than energy gap then is absorbed, and dissipates but its too much energy is a form with heat.Be to increase photoelectric cell efficient, " gang type " battery or connect the face battery more and be used to widen wavelength region.In addition; Compare with many thin film techniques; The energy gap of polysilicon, cadmium telluride or copper-indium-gallium-selenium semiconductor material is different from silicon single crystal, and it can change into electric energy with being lower than the 360nm wavelength, and the encapsulants that can see through the 360nm wavelength is very necessary for keeping PV module efficient.The EVA molecular structural formula
Polyvinyl butyral acetal (PVB) material possesses high sharpness (low mist degree), highly anti-impact and impermeabilisation, and to the excellent adhesion of glass, low moisture absorption, high anti-steam, and the stability that does not rely on Changes in weather.But there is shortcoming in PVB, and PVB is the water vapor sensitive type, increases inner membrance humidity and will cause the increase of mist property, and when finally being laminated into the sheet glass goods, cause bubble.This problem shows obviously at lamination film-making edge, and along with the time increases, bubble increases.Can alleviate to a certain extent through using special control techniques.Other shortcomings of PVB be in film process for the demand of fluidizer, fluidizer will produce migration, and finally causes leafing, in addition, the shock resistance of PVB film has temperature dependency, along with temperature descends and reduces.
The PVB molecular structural formula
With the metallocene catalyst is the PE (mPE) that the basis makes, and the product density scope can be by extra-low density (0.880g/cm
3) to high-density (0.980 g/cm
3), molecular weight also can be adjusted as required, and with metallocene catalyst synthesizing linear low-density polyethylene (LLDPE), because be single avtive spot, the LLDPE narrow molecular weight distribution that obtains, composition is evenly distributed.MPE (metallocene PE) possesses the superelevation volume specific resistance, low Leakage Current, and higher damp and hot performance, lower to the chemical corrosion degree of welding, low-moisture permeability, advantages such as reasonable price.Especially, mPE substitutes that traditional E VA glued membrane can be evaded the xanthochromia that caused by acetic acid group in the molecular structure and because the chemical corrosion for welding that is caused is revealed in small molecules acid, is used for photovoltaic and encapsulates so it can be used as a kind of novel glued membrane.
Summary of the invention
One of this patent purpose is to provide a kind of mPE glued membrane to replace conventional EVA glued membrane as a kind of type material to be used for rigidity photovoltaic module encapsulation, thereby reaches corrosion-resistant, hydrolysis, the effect that improves safety performance and reduce cost.
Two of the object of the invention is to provide a kind of replaceable conventional EVA glued membrane to be used for the preparation method of the novel photovoltaic packaging adhesive film of rigidity photovoltaic module encapsulation.
Three of the object of the invention is to provide the method for use of this kind film.
The present invention seeks to realize like this: a kind of novel photovoltaic packaging adhesive film, its raw material comprises:
100 parts of mPE resins
Linking agent 0.2-8.4 part
Tackifier 0.01-4 part
Oxidation inhibitor 0.05-5 part
Photostabilizer 0.01-0.5 part
The mPE starting material are to adopt the metallocene catalyst catalysis of ExxonMobil Chemical to make, and its melt flow rate(MFR) is 30g/10min (JIS K6922-2), density (under 25 ℃ of conditions) 0.880g/cm
3, the DSC fusing point is 58-60 ℃.
Said linking agent is the mixture of following one or several above arbitrary proportion: 1, and 1-two (tert-butyl hydroperoxide)-3,3,5-trimethyl-cyclohexane; 1,1-two (tert-butyl hydroperoxide) hexanaphthene, 4; Two (tert-butyl hydroperoxide) butyl valerates of 4-, Di Cumyl Peroxide 99, two (2-tert-butyl hydroperoxide sec.-propyl) benzene; 2,5-dimethyl--2,5-two (tert-butyl hydroperoxide) hexane.
Said tackifier are one of following or several kinds mixture wherein: r-glycidyl ether oxygen propyl trimethoxy silicane, vinyl trichloro silane, vinyltriethoxysilane, vinyl three (2-methoxy ethoxy) silane, γ-methacryloxypropyl trimethoxy silane, 3-sulfenyl propyl trimethoxy silicane, N-(β-aminoethyl)-γ-An Bingjisanjiayangjiguiwan.
Said oxidation inhibitor is the mixture of following one or several arbitrary proportion: butylated hydroxytoluene, four [β-(3, the 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol ester, 1; 3,5-three (3, the 5-di-tert-butyl-4-hydroxyl benzyl) tricarbimide, β-(3; The 5-di-tert-butyl-hydroxy phenyl) the positive octadecanol ester of propionic acid, three (2.4-di-tert-butyl-phenyl) phosphorous acid ester, two [2-methyl-4,6-two (1; The 1-dimethyl ethyl) phenol] phosphoric acid ethyl fat, four (2,4-di-t-butyl eight alkoxyl groups-4,4-xenyl) SULPHOSUCCINIC ACID ESTER; Two (2, the 4-di-tert-butyl-phenyl) pentaerythritol diphosphites, (2,4; 6-tri-tert-2-butyl-2-ethyl)-1, ammediol phosphorous acid ester, two (2,4-two p-isopropyl phenyl) pentaerythritol bis-phosphite; Four (2,4-di-tert-butyl-phenyl-4,4-xenyl) biphosphonate.
Said photostabilizer is one of following or several kinds mixture wherein: UV-531,2-(2 '-hydroxyl-3 ', 5 '-two uncle's phenyl)-5-chlorination benzotriazole; Three (1,2,2; 6,6-Pempiten base) phosphorous acid ester, 4-benzoyloxy-2; 2,6, the 6-tetramethyl piperidine.
This glued membrane prepares as follows:
(1) photostabilizer and oxidation inhibitor are mixed;
(2) crosslinking and curing agent and mPE pellet are mixed;
The mixture that remaining material and above-mentioned (1) are obtained joins in (2), carries out blend after mixing and extrudes, and temperature is controlled at 140-200 ℃, and extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process.
The invention has the beneficial effects as follows:
1, required auxiliary agent obviously reduces than the EVA glued membrane in the novel mPE glued membrane of the present invention, effectively raises security, and has reduced cost;
2, mPE glued membrane of the present invention is compared with EVA, no acetic acid group in the molecular structure, so its volume specific resistance will significantly improve than EVA, leakage rate descends; Secondly, no acetic acid small molecules overflows in the use, effectively reduces the extent of corrosion to welding; Because molecular chain polarity reduces, and will effectively reduce the water molecules transmitance.
Specific embodiments:
Below in conjunction with the practical implementation example the present invention is described further, but protection scope of the present invention is not limited in this;
Embodiment 1:
Get 0.8 part 1,1-two (tert-butyl hydroperoxide)-3,3; 5-trimethyl-cyclohexane and 100 parts of mPE pellets (MFR=30g/10min) mix, and get mass fraction and be (2 of 0.8 four [β-(3, the 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol esters and 0.05; 4,6-tri-tert-2-butyl-2-ethyl)-1, the ammediol phosphorous acid ester mixes; And with mixture together with 1.5 parts of tackifier 3-glycidyl ether oxygen base propyl trimethoxy silicanes, join in the mPE pellet that contains linking agent blend and extrude, temperature is controlled at 140-200 ℃; Extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process, glued membrane called after E1.
Embodiment 2:
Get 0.8 part 1,1-two (tert-butyl hydroperoxide)-3,3,5-trimethyl-cyclohexane and 100 parts of mPE pellets (MFR=30g/10min) mix; Get total mass number and be 0.1 UV-531 and total mass number and be 0.03 three (1,2,2; 6,6-Pempiten base) phosphorous acid ester mixes, with the photostabilizer that mixes and 0.8 part of four [β-(3; The 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol ester, 0.05 (2,4,6-tri-tert-2-butyl-2-ethyl)-1; The ammediol phosphorous acid ester mixes, and with mixture together with 1.5 parts of tackifier 3-glycidyl ether oxygen base propyl trimethoxy silicanes, join in the mPE pellet that contains linking agent blend and extrude; Temperature is controlled at 140-200 ℃, and extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process, glued membrane called after E2.
Embodiment 3:
Select commercially available aerosil as the nucleation transparent agent; With mass fraction is that 0.1 nucleation transparent agent aerosil directly joins in 1.5 parts of tackifier 3-glycidyl ether oxygen base propyl trimethoxy silicanes and mixes; Join in 100 parts of mPE pellets (MFR=30g/10min) and mix, in mixture, add 0.8 part 1,1-two (tert-butyl hydroperoxide)-3; 3, the 5-trimethyl-cyclohexane.Get total mass number and be 0.1 UV-531 and total mass number and be 0.03 three (1,2,2; 6,6-Pempiten base) phosphorous acid ester mixes, with the photostabilizer that mixes and 0.8 part of oxidation inhibitor four [β-(3; The 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol ester, 0.05 (2,4,6-tri-tert-2-butyl-2-ethyl)-1; The ammediol phosphorous acid ester joins in the mPE pellet blend in the lump and extrudes; Temperature is controlled at 140-200 ℃, and extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process, glued membrane called after E3.
Embodiment 4:
Get 0.4 part of tert-butyl hydroperoxide carbonic acid-2-ethylhexyl and 100 parts of mPE pellets (MFR=30g/10min) and mix, get total mass number and be 0.1 UV-531 and total mass number and be 0.03 three (1,2; 2,6,6-Pempiten base) phosphorous acid ester mixes; With (2,4 of the photostabilizer that mixes and 0.8 part of four [β-(3, the 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol ester and 0.05 part; 6-tri-tert-2-butyl-2-ethyl)-1, the ammediol phosphorous acid ester mixes, and with mixture together with 0.5 part of tackifier 3-glycidyl ether oxygen base propyl trimethoxy silicane; Joining in the mPE pellet that contains linking agent blend extrudes; Temperature is controlled at 140-200 ℃, and extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process, glued membrane called after E4.
Embodiment 5:
Get 0.8 part 1,1-two (tert-butyl hydroperoxide)-3,3; 5-trimethyl-cyclohexane and 100 parts of mPE pellets (MFR=3.5g/10min) mix, get total mass number and be 0.1 UV-531 and total mass number and be 0.03 three (1,2; 2,6,6-Pempiten base) phosphorous acid ester mixes; With the photostabilizer that mixes and 0.8 part of four [β-(3, the 5-di-tert-butyl-hydroxy phenyl) propionic acid] pentaerythritol ester, 0.05 part (2,4; 6-tri-tert-2-butyl-2-ethyl)-1, the ammediol phosphorous acid ester mixes, and with mixture together with 1.5 parts of tackifier 3-glycidyl ether oxygen base propyl trimethoxy silicanes; Joining in the mPE pellet that contains linking agent blend extrudes; Temperature is controlled at 140-200 ℃, and extrudate obtains glued membrane through curtain coating, cooling, traction, coiling process, glued membrane called after E5.
Comparative example 1-5; Its difference only is that example 1 does not add photostabilizer, has added photostabilizer in the example 2, and example 3 has been added commercially available aerosil as the nucleation transparent agent on routine 2 bases; Example 4 changes than linking agent in the example 2 to some extent, and example 5 is than used mPE pellet difference in the example 2.
Performance test scheme and result:
(1) compares E1 and E2 transmittance
The sample preparation standard: cut E1 and E2 respectively, specification 6.5cm*13cm cuts PV glass to appropriate size; Stack according to glass/mPE/ glass, vacuumize 6min under the 140 degree conditions, pressurization 30s, lamination 11min.
Test result is following: (referring to Fig. 1)
Compare E1 and E2 uv irradiation (0.63W/m
2, 60 ℃) and the 1000hYI variation:
Carry out the uv irradiation burn-in test according to International Electrotechnical Commission Standard IEC61345 specified requirement: test condition:
60 ± 5 ℃ of specimen surface temperature, test period 1000h
Wavelength is: 280-400nm, irradiation intensity are 0.63W/ m
2
Xanthochromia index (YI) is tested by GB2409-80 " plastics yellowness index TP ".
Table 1 E1 and E2 film uv irradiation (0.63W/m
2, 60 ℃) and the 1000hYI changing value
Mechanism: general plastics absorb the ultraviolet ray of 290-400nm in processing and use, and the initiation photoxidation is worn out and caused degraded.See the ultraviolet ray that does not absorb more than the 290nm from poly chemical structure; But in poly production and processing; Some residues and chromophoric group; Like residual catalyzer, carbonyl, unsaturates and hydroperoxide, it is aging to cause the Vilaterm photoxidation, therefore is used for outdoor polyethylene products and should carries out Photostabilised processing.Photoaging mechanism is under the effect of UV-light, to produce radical, and radical and oxygen effect produce peroxylradicals, and peroxylradicals forms superoxide and radical with the macromolecular chain effect again, and then forms chain reaction.
Through comparing E1 and E2 transmittance data and 1000hYI value, can find out and add the fast light aging that causes that a certain amount of photostabilizer helps improving mPE.
(2) compare E2 and E3 transmittance data
The sample preparation standard: cut E1 and E2 respectively, specification 6.5cm*13cm cuts PV glass to appropriate size; Stack according to glass/mPE/ glass, vacuumize 6min under the 140 degree conditions, pressurization 30s, lamination 11min.
Test result is following: (referring to Fig. 2)
The result shows the E3 light transmittance values a little more than E2, and this result is owing among the E3 nucleation transparent agent is arranged.
Mechanism: the nucleation transparent agent is the new functional agent of macromolecular material.Present application still is confined to imperfect crystal plastics such as Vilaterm, Vestolen PP 7052; Through changing the crystallization behavior of resin; Accelerate crystallization rate; Increase crystal density and impel fine grain sizeization, reach the shortening shaping cycle, improve physical and mechanical propertiess such as the goods transparency, surface luster, tensile strength, rigidity, heat-drawn wire, shock resistance, creep resistance.Transparent agent is a kind of of nucleator, and they are distributed in the system as more tiny nucleus, when crystal grain during less than light wave, has just reduced scattering of light, has increased the transparency of plastics.
Silicon-dioxide is the supporting material of typical rubber type of material.When the abundant refinement of silicon-dioxide particle diameter and after surface treatment, demonstrate the anti-reflection performance of stronger UVA and nucleation again.(purity is more than 99.99% to select high-purity nm silicon-dioxide for use; The metallic impurity total amount is less than 10ppm, and particle diameter is less than 80nm) as the nucleation transparent agent, in the mPE glued membrane both as nucleus; Increase transmittance; Form with crosslinked center exists again, has improved intermolecular linkage force, makes film structure more stable.
(3) compare E2 and E4 vulcanization curve, referring to Fig. 3
Through comparing vulcanization curve among E2 and the E4, can find out that E4 curing time (TC90) is shorter, solidify the processing required time and obviously be less than E2, this is because due to the linking agent difference.
(4) peel strength data of comparison E2 and E52000h
The following performance of main test is following:
(1) wet and heat ageing resistant performance
With sample by GB/T 2423.3 experimental techniques carry out hydrothermal aging test (85 ℃, 85RH% 2000h), takes out sample by timing node and carries out stripping strength according to GB/T 2790 experimental techniques and detect, the result is referring to Fig. 4.
Through relatively, that test result shows is two eight or five (promptly 85 ℃, 85RH%) sample E2 stripping strength descends very obviously behind the aging 2000h, and that the stripping strength of E5 descends is slower, this be vary in size because of different mPE pellet molecular weight due to.