CN106206795A - 一种用于大系统光伏组件的高阻水易清洁背板材料 - Google Patents
一种用于大系统光伏组件的高阻水易清洁背板材料 Download PDFInfo
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- CN106206795A CN106206795A CN201610533567.4A CN201610533567A CN106206795A CN 106206795 A CN106206795 A CN 106206795A CN 201610533567 A CN201610533567 A CN 201610533567A CN 106206795 A CN106206795 A CN 106206795A
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- photovoltaic module
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Abstract
本发明公开了一种用于大系统光伏组件的高阻水易清洁背板材料,所述背板材料依次由外层、粘接层、基膜层以及内层组成;外层由第四主体树脂、接枝助剂、无机填料和接枝于第四主体树脂表面的改性聚合物刷组成;本发明制得的背板材料的局部放电电压大于1500V可用于大系统光伏组件中,降低发电成本,提高发电效率;同时具有较低的水汽透过率,能够在潮湿的环境中长期使用,改善蜗牛纹、PID等现象;其外表面还具有很好的易清洁性能,在光伏组件长期户外使用过程中能够保持洁净的外观。此外,本发明制得的背板材料还具有高反射率、优异的耐候性和与EVA胶膜间的高粘结性,是一种综合性能优异的适用于大系统光伏组件的背板材料。
Description
技术领域
本发明涉及一种用于大系统光伏组件的高阻水易清洁背板材料,属于光伏封装材料领域。
背景技术
随着煤、石油、天然气等石化燃料的日益枯竭和环境污染日益严重,大力发展新能源已经成为一项全球化的重要任务。近年来,作为绿色能源的代表,太阳能发电越来越受到人们关注。目前对于太阳能的应用主要是通过太阳能发电组件将太阳能转化为电能,太阳能发电组件主要由低铁钢化玻璃、前层EVA胶膜、太阳能电池片、后层EVA胶膜和背板组成。其中,背板起到水汽阻隔性、电气绝缘性、与EVA的粘结性、耐候性等保护电池片的作用。
但是,目前市场上光伏背板的局部放电电压通常在600~1000VDC左右,仅能适应常规的光伏组件系统,对于较大系统的光伏组件存在很大的安全隐患,因此研发一种具有高部局放电电压的光伏背板对光伏组件成本的降低非常有必要。已经有一些关于高系统背板的报道,比如专利CN201320878102.4中所述采用增加背板基材层的厚度来提高背板的局放电压,这种方法会导致后期加工困难和制作成本增加等问题并且水汽透过率也只能维持在2g/m2·d左右容易引发蜗牛纹、PID等现象出现;专利CN201110316402.9采用玻璃纤维布来赋予背板高耐压性从而来提高背板的局部放电电压,但是该方案存在工艺繁琐、生产成本高等缺点。目前的解决方案,还不够全面,没有办法在做到高压可靠性的同时还兼顾较多的其他功能性。另常规背板所用的耐候层一般都为氟碳涂料或者氟膜等一些表面能低的物质,这样的背板抗污能力弱在氢键、色散力和憎水作用下使一些碳酸盐、硫酸盐、硅酸盐、蛋白质、天然高分子等一些有机无机污染物能够轻易的粘附在背板表面并难以清洗从而影响背板散热,降低太阳能电池的安全性,同时也给去除这些杂质增加了人工成本。
因而,开发出一款低成本、耐高压、易清洁并且适用于大系统光伏组件的背板材料是本领域技术人员亟待解决的重大课题。
发明内容
本发明针对现有技术的不足,通过改变背板内外层的组成、结构从而提供了一种生产工艺简单、生产成本低,同时具有高局部放电电压、水汽阻隔性和易清洁性能的光伏组件背板,这种背板在光反射性、粘结强度、耐候性等方面也具有良好的效果。
本发明的目的是通过以下技术方案实现的:一种用于大系统光伏组件的高阻水易清洁背板材料,依次由外层、粘结层、基膜层以及内层组成;内层和基膜层可以通过熔融涂覆、流延成膜或双层共挤出连接,外层通过粘接层粘结到基膜层;所述外层厚度为50~200μm,粘结层厚度为5~20μm,基膜层厚度为100~500μm,内层厚度为100~400μm。
所述内层由100重量份的第一主体树脂、5~20重量份的第二主体树脂、3~30重量份的主体填料、3~30重量份的辅助填料、0.01~1重量份的硅烷偶联剂、0.001~0.1重量份的交联剂、0.001~0.1重量份的抗热氧老化剂、0.001~0.1重量份的光稳定剂组成;所述的第一主体树脂由乙烯与丙烯、丁烯、戊烯、辛烯中的一种或多种按照任意配比共聚之后组成,所述第二主体树脂由聚丙烯酸、聚丙烯酸甲酯、聚甲基丙烯酸甲酯、聚异丁烯、聚异戊二烯、聚丁二烯中的一种或几种混合组成;
所述基膜层由第三主体树脂、无机填料、水解稳定剂、抗热氧老化剂组成;所述第三主体树脂由聚酰胺、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二酯、聚萘二甲酸丁二醇酯、聚甲基丙烯酸甲酯、聚对苯二甲酸环己二甲酯、聚对苯二甲酸丙二酯中的一种或多种按任意配比混合组成;
所述粘结层由聚氨酯胶黏剂、环氧树脂胶黏剂、丙烯酸酯胶黏剂和有机硅树脂胶黏剂中的一种或几种混合组成;
所述外层由第四主体树脂、接枝助剂、无机填料和接枝于第四主体树脂表面的亲水性聚合物刷所组成;所述第四主体树脂由单氟乙烯树脂、偏氟乙烯树脂、三氟氯乙烯树脂、聚四氟乙烯树脂、单氟乙烯-乙烯基醚共聚物、单氟乙烯-乙烯基酯共聚物、偏氟乙烯-乙烯基醚共聚物、偏氟乙烯-乙烯基酯共聚物、三氟氯乙烯-乙烯基醚共聚物、三氟氯乙烯-乙烯基酯共聚物、四氟乙烯-乙烯基醚共聚物中的一种或多种按任意比组成;所述亲水性聚合物刷为聚丙烯酸、聚丙烯酸甲酯、聚甲基丙烯酸甲酯、聚丙烯酸丁酯、聚丙烯酰胺、聚N-羟乙基丙烯酰胺、聚N-羟甲基丙烯酰胺、聚甲基丙烯酸缩水甘油酯、聚甲基丙烯酸羟乙酯中的一种或几种组成;
进一步地,所述主体填料由氧化钛、锌钡白、云母粉、滑石粉、氧化锌、氧化镁、瓷粉、蒙脱土、碳酸钙中的一种或几种按照任意比混合组成;所述辅助填料由粒径为1~10μm的沸石、介孔二氧化硅、空心玻璃微球、空心陶瓷微球中的一种或多种按照任意比混合组成;所述无机填料为钛白粉、云母粉、滑石粉、金属氧化物、瓷粉、蒙脱土、碳酸钙、沸石、铁铬黑、铜铬黑、炭黑一种或几种和粒径为1~10μm的介孔二氧化硅、空心玻璃微球、空心陶瓷微球中的一种或多种按照任意比混合组成;
进一步地,所述硅烷偶联剂由3-三乙氧基甲基硅烷基-1-丙胺、γ-缩水甘油醚氧丙基三甲氧基硅烷、γ-甲基丙烯酰氧基丙基三甲氧基硅烷、乙烯基三甲氧基硅烷、乙烯基三(β-甲氧基乙氧基)硅烷、乙烯基三乙氧基硅烷、乙烯基三异丙氧基硅烷、乙烯基三异丙烯氧基硅烷、甲基乙烯基二乙氧基硅烷、甲基乙烯基二甲氧基硅烷、二乙烯三氨基丙基三甲氧基硅烷中的一种或多种按任意比组成。
进一步地,所述交联剂由过氧化苯甲酰、过氧化丁基异丙苯、2,5-二甲基-2,5-双(苯甲酰过氧)-己烷、3,3-双(叔丁基过氧)丁酸乙酯、邻,邻-叔丁基-邻-异丙基-单-过氧化碳酸酯、正丁基4,4-二(过氧化叔丁基)戊酸酯、乙二醇双甲基丙烯酸酯、二乙烯基苯、三甲基丙烷三甲基丙烯酸酯、季戊四醇三丙烯酸酯、季戊四醇三丙烯酸酯、四乙基硅烷、N,N-亚甲基双丙烯酰酯胺中的一种或多种按照任意配比组成。
进一步地,所述抗热氧老化剂由2,2-亚甲基-双-(4-甲基-6-叔丁基)苯酚、1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)、3,5-二叔丁基-4-羟基-苯甲酸十六烷基酯、二硬酯基季戊四醇二亚磷酸酯、双酚A双(二苯基磷酸酯)中的一种或多种按照任意配比组成。
进一步地,所述光稳定剂由癸二酸双-2,2,6,6-四甲基哌啶醇酯、双-1-癸烷氧基-2,2,6,6-四甲基哌啶-4-醇葵二酸酯、N,N’-双(2,2,6,6-四甲基-4-哌啶基)-1,6-己二胺与2,4-二氯-6-6(4-吗啉基)-1,3,5-三嗪的复配物、甲基-1,2,2,6,6-五甲基-4-哌啶基癸二酸中的一种或多种按任意配比组成。
进一步地,所述水解稳定剂由单体碳化二亚胺类水解稳定剂、噁唑啉类化合物水解稳定剂、环氧化合物类水解稳定剂中的一种或多种按任意比混合组成。
进一步地,所述接枝助剂为2-羟基-甲基苯基丙烷-1-酮、1-羟基环己基苯基甲酮、2-甲基-1-(4-甲硫基苯基)-2-吗啉基-1-丙酮、安息香双甲醚BDK、2,4,6-三甲基苯甲酰基二苯基氧化膦、4-(N,N-二甲氨基)苯甲酸乙酯、二本甲酮BP、4-氯二苯甲酮、4-甲基二苯甲酮、邻苯甲酰基苯甲酸甲酯、4-苯基二苯甲酮、2,4,6-三甲基苯甲酰基-二苯基氧化膦、2,4,6-三甲基苯甲酰基苯基膦酸乙酯中的一种或几种混合组成;
进一步地,所述接枝的方法由光引发接枝、电晕引发接枝、等离子体处理引发接枝、高能辐射引发接枝中的一种或几种交替进行。
本发明的有益效果主要体现在:本发明制备出的一种用于大系统光伏组件的高阻水易清洁背板材料在具有高局部放电电压、水汽阻隔性能和易清洁性能的同时在光反射性、粘结强度和户外耐候性等方面也有突出优势,为光伏组件背板材料提供了新思路、新方法。本发明通过改变背板内外层的组成、结构,提供一种局部放电电压高、水汽透过率低并且具有易清洁性能的适用于大系统光伏组件用的光伏背板;该背板在具有高局放电压、高水汽阻隔和易清洁性能的同时还具有较高的光反射性、粘结强度和良好的耐候性,能够充分发挥背板的保护作用。
具体实施方式
本发明中的内层、基膜层可以由熔融涂覆或流延成膜或双层共挤出制得,外层通过粘接层粘结到基膜层。
实施例1:
外层:聚偏氟乙烯膜接枝聚丙烯酸接枝聚N-羟乙基丙烯酰胺,厚度100μm;
粘结层:聚氨酯胶黏剂,厚度10μm;
基膜层:聚对苯二甲酸乙二醇酯,厚度200μm;
内层:第一主体树脂乙丙共聚物和聚异丁烯的混合物100份,反射填料钛白粉8份,辅助填料介孔二氧化硅6份,硅烷偶联剂乙烯基三甲氧基硅烷2份,交联剂过氧化丁基异丙苯0.5份,抗热氧老化剂0.05份,光稳定剂0.05份,紫外吸收剂0.05份,厚度150μm。
实施例2:
外层:聚偏氟乙烯膜接枝聚N-羟乙基丙烯酰胺,厚度100μm;
粘结层:聚氨酯胶黏剂,厚度10μm;
基膜层:聚对苯二甲酸乙二醇酯,厚度200μm;
内层:第一主体树脂乙丙共聚物和聚异丁烯的混合物100份,反射填料钛白粉8份,辅助填料介孔二氧化硅6份,硅烷偶联剂乙烯基三甲氧基硅烷2份,交联剂过氧化丁基异丙苯0.5份,抗热氧老化剂0.05份,光稳定剂0.05份,紫外吸收剂0.05份,厚度150μm。
实施例3:
外层:聚偏氟乙烯膜接枝聚丙烯酸,厚度100μm;
粘结层:聚氨酯胶黏剂,厚度10μm;
基膜层:聚对苯二甲酸乙二醇酯,厚度200μm;
内层:第一主体树脂乙丙共聚物和聚异丁烯的混合物100份,反射填料钛白粉8份,辅助填料介孔二氧化硅3份,硅烷偶联剂乙烯基三甲氧基硅烷2份,交联剂过氧化丁基异丙苯0.5份,抗热氧老化剂0.05份,光稳定剂0.05份,紫外吸收剂0.05份,厚度150μm。
实施例4:
外层:聚偏氟乙烯膜接枝聚丙烯酸,厚度100μm;
粘结层:聚氨酯胶黏剂,厚度10μm;
基膜层:聚对苯二甲酸乙二醇酯,厚度200μm;
内层:第一主体树脂乙丙共聚物和聚异丁烯的混合物100份,辅助填料介孔二氧化硅6份,硅烷偶联剂乙烯基三甲氧基硅烷2份,交联剂过氧化丁基异丙苯0.5份,抗热氧老化剂0.05份,光稳定剂0.05份,紫外吸收剂0.05份,厚度150μm。
比较例1:
市场购得的KPK结构背板
采用以上方法制得背板材料,性能指标通过以下方法测定:
1、光反射率
按照GB/T13452.3-92、GB/T9270-88、GB/T5211.17-88、ISO3906-80标准设计的反射率测定仪进行测试。
2、局放电压
按照标准IEC61730《光伏(PV)组件安全鉴定》进行测试。
3、水汽透过率
按照标准ASTM F1249《用调制红外线传感器测定塑料膜和薄板水蒸气透过性的试验方法》进行测试。
试验条件:﹢38℃,相对湿度100%
4、与EVA的剥离强度
按照GB/T2790进行剥离强度测试。
5、水接触角
按照GB/T30693-2014进行测试。
6、恒定耐湿热老化性能
按照标准GB/T2423.3《高低温湿热试验方法》
试验条件:﹢85℃,相对湿度85%
试验前后对试样黄变指数(△YI)按照国标GB 2409《塑料黄变指数试验方法》测定对实施例1、2、3、4和比较例1进行性能检测,结果如表1所示。
表1:制得背板材料的性能参数
由表中数据可知,本发明一种用于大系统光伏组件的高阻水易清洁背板材料,在通过改变背板内层的组成相对于普通背板在局部放电、阻水性、反射率等方面有明显提高,并且当对背板外层进行亲水改性之后能够有效的降低背板外层的水接触角提高抗污能力。本发明的一种用于大系统光伏组件的高阻水易清洁背板材料的局放电压、水汽阻隔性高,能够满足不同系统大小光伏组件的要求,降低光伏组件的生产成本,有效的解决蜗牛纹、PID等现象提高了安全性;同时由于其特殊设计的外表面还具有很好的易清洁性能,在光伏组件长期户外使用过程中能够保持洁净的外观。此外其在光反射性、粘结强度、耐候性等方面也有突出优势,能够很好的满足光伏组件背板的要求。
Claims (8)
1.一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,依次由外层、粘接层、基膜层以及内层组成;内层和基膜层可以通过熔融涂覆、流延成膜或双层共挤出连接,外层通过粘接层粘结到基膜层。
所述内层厚度为100~400μm,由100重量份的第一主体树脂、5~20重量份的第二主体树脂、3~30重量份的主体填料、3~30份的辅助填料,0.01~1重量份的硅烷偶联剂、0.001~0.1重量份的交联剂、0.001~0.1重量份的抗热氧老化剂、0.001~0.1重量份的光稳定剂等组成;所述的第一主体树脂由乙烯与丙烯、丁烯、戊烯、辛烯中的一种或多种按照任意配比共聚组成;所述第二主体树脂由聚丙烯酸、聚丙烯酸甲酯、聚甲基丙烯酸甲酯、聚异丁烯、聚异戊二烯、聚丁二烯中的一种或几种按照任意配比共混组成。
所述基膜层厚度为100~500μm,由第三主体树脂、无机填料、水解稳定剂、抗热氧老化剂等组成;所述第三主体树脂由聚酰胺、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二酯、聚萘二甲酸丁二醇酯、聚甲基丙烯酸甲酯、聚对苯二甲酸环己二甲酯、聚对苯二甲酸丙二酯中的一种或多种按任意配比混合组成。
所述粘接层厚度为5~20μm,由聚氨酯胶黏剂、环氧树脂胶黏剂、丙烯酸酯胶黏剂和有机硅树脂胶黏剂中的一种或几种按任意配比混合组成。
所述外层厚度为50~200μm,由第四主体树脂、接枝助剂、无机填料和接枝于第四主体树脂表面的改性聚合物刷等组成;所述第四主体树脂由单氟乙烯树脂、偏氟乙烯树脂、三氟氯乙烯树脂、聚四氟乙烯树脂、单氟乙烯-乙烯基醚共聚物、单氟乙烯-乙烯基酯共聚物、偏氟乙烯-乙烯基醚共聚物、偏氟乙烯-乙烯基酯共聚物、三氟氯乙烯-乙烯基酯共聚物、四氟乙烯-乙烯基醚共聚物中的一种或多种按任意比组成;所述聚合物刷由聚丙烯酸、聚丙烯酸甲酯、聚甲基丙烯酸甲酯、聚丙烯酸丁酯、聚丙烯酰胺、聚N-羟乙基丙烯酰胺、聚N-羟甲基丙烯酰胺、聚甲基丙烯酸缩水甘油酯、聚甲基丙烯酸羟乙酯中的一种或几种按任意比混合组成。
2.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述主体填料由氧化钛、锌钡白、云母粉、滑石粉、氧化锌、氧化镁、瓷粉、蒙脱土、碳酸钙中的一种或几种组成按照任意比混合组成;所述辅助填料由平均粒径在1~10μm范围内的沸石、介孔二氧化硅、空心玻璃微球、空心陶瓷微球中的一种或多种按照任意比混合组成;所述无机填料为钛白粉、云母粉、滑石粉、金属氧化物、瓷粉、蒙脱土、碳酸钙、沸石、铁铬黑、铜铬黑、炭黑一种或几种和粒径为1~10μm的介孔二氧化硅、空心玻璃微球、空心陶瓷微球中的一种或多种按照任意比混合组成。
3.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述硅烷偶联剂由3-三乙氧基甲基硅烷基-1-丙胺、γ-缩水甘油醚氧丙基三甲氧基硅烷、γ-甲基丙烯酰氧基丙基三甲氧基硅烷、乙烯基三甲氧基硅烷、乙烯基三(β-甲氧基乙氧基)硅烷、乙烯基三乙氧基硅烷、乙烯基三异丙氧基硅烷、乙烯基三异丙烯氧基硅烷、甲基乙烯基二乙氧基硅烷、甲基乙烯基二甲氧基硅烷、二乙烯三氨基丙基三甲氧基硅烷中的一种或多种按任意比组成。
4.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述交联剂由过氧化苯甲酰、过氧化丁基异丙苯、2,5-二甲基-2,5-双(苯甲酰过氧)-己烷、3,3-双(叔丁基过氧)丁酸乙酯、邻,邻-叔丁基-邻-异丙基-单-过氧化碳酸酯、正丁基4,4-二(过氧化叔丁基)戊酸酯、乙二醇双甲基丙烯酸酯、二乙烯基苯、三甲基丙烷三甲基丙烯酸酯、季戊四醇三丙烯酸酯、季戊四醇三丙烯酸酯、四乙基硅烷、N,N-亚甲基双丙烯酰酯胺中的一种或多种按照任意配比组成。
5.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述抗热氧老化剂由2,2-亚甲基-双-(4-甲基-6-叔丁基)苯酚、1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)、3,5-二叔丁基-4-羟基-苯甲酸十六烷基酯、二硬酯基季戊四醇二亚磷酸酯、双酚A双(二苯基磷酸酯)中的一种或多种按照任意配比组成。
6.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述光稳定剂由癸二酸双-2,2,6,6-四甲基哌啶醇酯、双-1-癸烷氧基-2,2,6,6-四甲基哌啶-4-醇葵二酸酯、N,N’-双(2,2,6,6-四甲基-4-哌啶基)-1,6-己二胺与2,4-二氯-6-6(4-吗啉基)-1,3,5-三嗪的复配物、甲基-1,2,2,6,6-五甲基-4-哌啶基癸二酸中的一种或多种按任意配比组成。
7.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述水解稳定剂由单体碳化二亚胺类水解稳定剂、噁唑啉类化合物水解稳定剂、环氧化合物类水解稳定剂中的一种或多种按任意比混合组成。
8.如权利要求1所述的一种用于大系统光伏组件的高阻水易清洁背板材料,其特征在于,所述接枝助剂由2-羟基-甲基苯基丙烷-1-酮、1-羟基环己基苯基甲酮、2-甲基-1-(4-甲硫基苯基)-2-吗啉基-1-丙酮、安息香双甲醚BDK、2,4,6-三甲基苯甲酰基二苯基氧化膦、4-(N,N-二甲氨基)苯甲酸乙酯、二本甲酮BP、4-氯二苯甲酮、4-甲基二苯甲酮、邻苯甲酰基苯甲酸甲酯、4-苯基二苯甲酮、2,4,6-三甲基苯甲酰基-二苯基氧化膦、2,4,6-三甲基苯甲酰基苯基膦酸乙酯中的一种或几种混合组成;所述接枝的方法由光引发接枝、电晕引发接枝、等离子体处理引发接枝、高能辐射引发接枝中的一种或几种交替进行。
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