CN106380545A - 一种gma接枝poe薄膜及其制备方法 - Google Patents
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Abstract
本发明公开了一种GMA接枝POE薄膜及其制备方法,将超声波发射装置设置在挤出机机筒或密练机机筒上,加工过程中发射超声波,超声波的空化作用产生强大的冲击力和能量,使得POE形成更多的大分子链自由基,自由基与GMA反应,从而POE的接枝率大大提高,可以应用于太阳能电池板的封装薄膜材料的制造。
Description
技术领域
本发明涉及一种POE薄膜,具体涉及一种GMA接枝POE薄膜及其制备方法,属于材料领域。
背景技术
作为可再生能源,太阳能由于无污染,储量无限,受到越来越多的应用。其中太阳能电池板是太阳能发电系统的核心部分,一般太阳能电池板由上层玻璃、EVA薄膜、太阳能电池、EVA薄膜、TPT背板。EVA薄膜起胶粘及阻隔水汽的作用但由于EVA含醋酸乙烯酯,在太阳光照下会老化变黄,影响透光率和粘接性能,进而影响太阳能电池的光电转换效率及使用寿命。故急需一种耐老化,具有持久粘接力的薄膜,提高太阳能电池的使用寿命,尽可能长时间不影响光电效率转换。POE薄膜无羰基、羧基、双键、叁键等易老化基团,被认为可能取代EVA薄膜用于太阳能电池板,但由于POE无极性基团,其和玻璃、太阳能电池、TPT背板的粘接力较差,而GMA中具有环氧基团,可以和玻璃、太阳能电池、TPT背板发生化学反应,故可以用GMA接枝POE薄膜,但由于接枝率较低,一般只有1%左右,粘接力不能满足太阳能电池的使用要求。
发明内容
解决的技术问题:针对EVA薄膜易老化黄变,影响太阳能电池的光电转换率及使用寿命,本发明提供一种接枝率在2%以上的高接枝率GMA接枝POE薄膜及其制备方法。
为了实现上述目标,本发明采用如下技术方案:
一种GMA接枝POE薄膜的制备方法,包含如下步骤:S1、以POE和抗氧剂、抗紫外线剂、碳酸钙及滑石粉中的一种或多种制得POE混合物;将DCP溶于混合有丙酮或未混合有丙酮的GMA中得混合溶液,再将所述混合溶液倒入POE或POE混合物中冷混至少3min出料,获得混合后的物料;S2、启动安装在挤出机机筒上的超声波发射装置,将所述混合后的物料加入挤出机中造粒备用;S3、以S2所获得的备用造粒料制造POE薄膜。
优选地,一种GMA接枝POE薄膜的制备方法,包含如下步骤:
S1、以POE和抗氧剂、抗紫外线剂、碳酸钙及滑石粉中的一种或多种制得POE混合物;将DCP溶于混合有丙酮或未混合有丙酮的GMA中得混合溶液;
S2、启动挤出机上的超声波发射装置,将混合溶液加入侧喂料系统,混合溶液均匀注入挤出机中,将POE混合物加入挤出机中造粒备用;
S3、以S2所获得的备用造粒料制造POE薄膜。
优选地,所述制备方法包含如下步骤:
S1、、以POE和抗氧剂、抗紫外线剂、碳酸钙及滑石粉中的一种或多种制得POE混合物;将DCP溶于混合有丙酮或未混合有丙酮的GMA中得混合溶液,再将所述混合溶液倒入POE或POE混合物中冷混至少3min出料,获得混合后的物料;S2、启动密炼机机筒上的超声波发射装置,将混合后的物料加入密炼机中混炼;S3、混炼完成的物料冷却后在破碎机中破碎备用;S4、以S3所获得的备用造粒料制造POE薄膜。
进一步地,将所述备用造粒料加入流延机中制备流延膜,该薄膜被用于制造具有耐候性的太阳能电池。
进一步地,所述一种GMA接枝POE薄膜,包含如下组分且各组分的重量分数分别为:POE:85-98份;GMA:0.5-5份;DCP:0.1-2份;丙酮:0-5份;抗氧剂:0.5-3份;抗紫外线剂:0.5-3份;碳酸钙:0-5份;滑石粉:0-5份。
优选地,所述挤出机的各区温度如下:一区60-160℃,二区90-160℃,三区100-180℃,四区130-200℃,五区150-200℃,六区150-220℃,七区150-250℃,八区150-250℃,九区150-250℃,十区150-200℃。
优选地,所述密炼机温度为150-220℃。
有益效果:本发明将超声波发射装置设置在挤出机机筒或密练机机筒上,加工过程中发射超声波,超声波的空化作用产生强大的冲击力和能量,使得POE形成更多的大分子链自由基,自由基与GMA反应,从而POE的接枝率大大提高,可以应用于太阳能电池板的封装薄膜材料的制造。
具体实施方式
下面通过实施例的方式进一步说明本发明。
实施例1
1、配料:将各组分按如下质量份数称重:POE:95.5份;GMA:1份;DCP:0.4份;抗氧剂:1份;抗紫外线剂:2份。将DCP放在GMA中溶解。
2、制备薄膜:将POE、抗氧剂和抗紫外线剂置于混料机中,再将溶解了DCP的GMA溶液倒入混料机中,冷混5分钟出料。开启设置在挤出机第五机筒、第六机筒和第七机筒上的超声波发射装置,超声波功率均为500W,将混合后的物料加入挤出机中造粒,各区温度(单位℃)如下:
一区 | 二区 | 三区 | 四区 | 五区 | 六区 | 七区 | 八区 | 九区 | 十区 |
70 | 100 | 130 | 150 | 170 | 190 | 200 | 190 | 185 | 180 |
造粒料最后加入流延机中制备流延膜。
实施例2
1、配料:将各组分按如下质量份数称重:POE:93份;GMA:1份;DCP:0.2份;丙酮:2.8份;抗氧剂:1份;抗紫外线剂:2份。将DCP放在GMA中溶解。
2、制备薄膜:将POE、抗氧剂和抗紫外线剂置于混料机中,再将溶解了DCP的GMA溶液倒入混料机中,冷混5分钟出料。开启设置在挤出机第五机筒、第六机筒和第七机筒上的超声波发射装置,超声波功率均为500W,将混合后的物料加入挤出机中造粒,各区温度(单位℃)如下:
一区 | 二区 | 三区 | 四区 | 五区 | 六区 | 七区 | 八区 | 九区 | 十区 |
70 | 100 | 130 | 150 | 170 | 190 | 200 | 190 | 185 | 180 |
造粒料最后加入流延机中制备流延膜。
实施例3
1、配料:将各组分按如下质量份数称重:POE:89.5份;GMA:5份;DCP:0.5份;抗氧剂:2份;抗紫外线剂:3份。将DCP放在GMA中溶解。
2、制备薄膜:将POE、抗氧剂和抗紫外线剂置于混料机中,再将溶解了DCP的GMA溶液倒入混料机中,冷混8分钟出料。开启设置在密练机上的超声波发射装置,超声波功率为800W,温度设置190度,密炼混合4分钟,出料冷却,后放入破碎机中破碎,破碎料最后加入流延机中制备流延膜。
实施例4
1、配料:将各组分按如下质量份数称重:POE:91.5份;GMA:3份;DCP:0.5份;抗氧剂:2份;抗紫外线剂:3份。将DCP放在GMA中溶解。
2、制备薄膜:将POE、抗氧剂和抗紫外线剂置于混料机中,再将溶解了DCP的GMA溶液倒入混料机中,冷混8分钟出料。开启设置在挤出机上的第五机筒、第六机筒、第七机筒和第八机筒上的超声波发射装置,超声波功率为500W,将混合后的物料加入挤出机中造粒,各区温度(单位℃)如下:
一区 | 二区 | 三区 | 四区 | 五区 | 六区 | 七区 | 八区 | 九区 | 十区 |
70 | 100 | 130 | 150 | 170 | 190 | 200 | 190 | 185 | 180 |
造粒料最后加入流延机中制备流延膜。
为了更好地说明本发明,采用行业内的标准测试方法对各实施例的流延膜进行接枝率测试,同时,结合对比例进行比较,对比例为市购无超声波处理的GMA接枝POE,测试结果见表1。
表1 实施例1-4及对比例测试结果对比
序号 | 实施例 | 接枝率 |
1 | 实施例1 | 1.8% |
2 | 实施例2 | 2.0% |
3 | 实施例3 | 2.2% |
4 | 实施例4 | 2.1% |
5 | 对比例 | 1.0% |
从表1可见,本发明的各实施例制备出的产品,产品的接枝率大大提高,说明超声波改性的产品具有良好的效果。
Claims (9)
1.一种GMA接枝POE薄膜的制备方法,其特征在于,包含如下步骤:
S1、以POE和抗氧剂、抗紫外线剂、碳酸钙及滑石粉中的一种或多种制得POE混合物;将DCP溶于混合有丙酮或未混合有丙酮的GMA中得混合溶液,再将所述混合溶液倒入POE或POE混合物中冷混至少3min出料,获得混合后的物料;
S2、启动安装在挤出机机筒上的超声波发射装置,将所述混合后的物料加入挤出机中造粒备用;
S3、以S2所获得的备用造粒料制造POE薄膜。
2.根据权利要求1所述一种GMA接枝POE薄膜的制备方法,其特征在于,包含如下步骤:
S1、以POE和抗氧剂、抗紫外线剂、碳酸钙及滑石粉中的一种或多种制得POE混合物;将DCP溶于混合有丙酮或未混合有丙酮的GMA中得混合溶液;
S2、启动挤出机上的超声波发射装置,将混合溶液加入侧喂料系统,混合溶液均匀注入挤出机中,将POE混合物加入挤出机中造粒备用;
S3、以S2所获得的备用造粒料制造POE薄膜。
3.根据权利要求1所述一种GMA接枝POE薄膜的制备方法,其特征在于,所述步骤S2为:启动密炼机机筒上的超声波发射装置,将混合后的物料加入密炼机中混炼;步骤所述S3为:混炼完成的物料冷却后在破碎机中破碎备用;还具有步骤S4,步骤S4、以S3所获得的备用造粒料制造POE薄膜。
4.根据权利要求1-3中任一项所述一种GMA接枝POE薄膜的制备方法,其特征在于:将备用造粒料加入流延机中制备流延膜。
5.根据权利要求1-3中任一项所述一种GMA接枝POE薄膜,其特征在于:包含如下组分且各组分的重量分数分别为:POE:85-98份;GMA:0.5-5份;DCP:0.1-2份;丙酮:0-5份。
6.根据权利要求1-3中任一项所述一种GMA接枝POE薄膜,其特征在于:包含如下组分且各组分的重量分数分别为:抗氧剂:0.5-3份;抗紫外线剂:0.5-3份;碳酸钙:0-5份;滑石粉:0-5份。
7.根据权利要求1或2所述一种GMA接枝POE薄膜,其特征在于:挤出机的各区温度如下:一区60-160℃,二区90-160℃,三区100-180℃,四区130-200℃,五区150-200℃,六区150-220℃,七区150-250℃,八区150-250℃,九区150-250℃,十区150-200℃。
8.根据权利要求3所述一种GMA接枝POE薄膜,其特征在于:密炼机温度为150-220℃。
9.根据权利要求1-3中任一项所述一种GMA接枝POE薄膜,其特征在于:所述GMA接枝POE薄膜被用于制造具有耐候性的太阳能电池。
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