CN107501706B - 一种p型双面电池封装胶膜 - Google Patents
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- 239000002313 adhesive film Substances 0.000 title claims abstract description 38
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- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims abstract description 54
- 239000000155 melt Substances 0.000 claims abstract description 19
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 18
- 239000003431 cross linking reagent Substances 0.000 claims abstract description 18
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 18
- 239000001301 oxygen Substances 0.000 claims abstract description 18
- 239000003381 stabilizer Substances 0.000 claims abstract description 18
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- -1 dioctadecyl-4-tert-butyl-3-hydroxy-2, 6-dimethylbenzylphosphonate Chemical compound 0.000 claims description 26
- 238000002834 transmittance Methods 0.000 claims description 22
- ZVUNTIMPQCQCAQ-UHFFFAOYSA-N 2-dodecanoyloxyethyl dodecanoate Chemical compound CCCCCCCCCCCC(=O)OCCOC(=O)CCCCCCCCCCC ZVUNTIMPQCQCAQ-UHFFFAOYSA-N 0.000 claims description 18
- 239000002202 Polyethylene glycol Substances 0.000 claims description 18
- XQBCVRSTVUHIGH-UHFFFAOYSA-L [dodecanoyloxy(dioctyl)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCCCCCC)(CCCCCCCC)OC(=O)CCCCCCCCCCC XQBCVRSTVUHIGH-UHFFFAOYSA-L 0.000 claims description 18
- 229920001223 polyethylene glycol Polymers 0.000 claims description 18
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical compound OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 claims description 16
- 239000012752 auxiliary agent Substances 0.000 claims description 15
- 239000003795 chemical substances by application Substances 0.000 claims description 15
- WOXXJEVNDJOOLV-UHFFFAOYSA-N ethenyl-tris(2-methoxyethoxy)silane Chemical compound COCCO[Si](OCCOC)(OCCOC)C=C WOXXJEVNDJOOLV-UHFFFAOYSA-N 0.000 claims description 13
- NOZAQBYNLKNDRT-UHFFFAOYSA-N [diacetyloxy(ethenyl)silyl] acetate Chemical compound CC(=O)O[Si](OC(C)=O)(OC(C)=O)C=C NOZAQBYNLKNDRT-UHFFFAOYSA-N 0.000 claims description 12
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 11
- JKIJEFPNVSHHEI-UHFFFAOYSA-N Phenol, 2,4-bis(1,1-dimethylethyl)-, phosphite (3:1) Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP(OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC1=CC=C(C(C)(C)C)C=C1C(C)(C)C JKIJEFPNVSHHEI-UHFFFAOYSA-N 0.000 claims description 10
- 150000001875 compounds Chemical class 0.000 claims description 10
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 9
- STEYNUVPFMIUOY-UHFFFAOYSA-N 4-Hydroxy-1-(2-hydroxyethyl)-2,2,6,6-tetramethylpiperidine Chemical compound CC1(C)CC(O)CC(C)(C)N1CCO STEYNUVPFMIUOY-UHFFFAOYSA-N 0.000 claims description 8
- VLKZOEOYAKHREP-UHFFFAOYSA-N methyl pentane Natural products CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 claims description 8
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- 239000001384 succinic acid Substances 0.000 claims description 8
- SAJFQHPVIYPPEY-UHFFFAOYSA-N 2,6-ditert-butyl-4-(dioctadecoxyphosphorylmethyl)phenol Chemical group CCCCCCCCCCCCCCCCCCOP(=O)(OCCCCCCCCCCCCCCCCCC)CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 SAJFQHPVIYPPEY-UHFFFAOYSA-N 0.000 claims description 7
- NPCRFXPZMMRNAA-UHFFFAOYSA-N 4-nonylphenol;phosphorous acid Chemical compound OP(O)O.CCCCCCCCCC1=CC=C(O)C=C1.CCCCCCCCCC1=CC=C(O)C=C1.CCCCCCCCCC1=CC=C(O)C=C1 NPCRFXPZMMRNAA-UHFFFAOYSA-N 0.000 claims description 7
- XITRBUPOXXBIJN-UHFFFAOYSA-N bis(2,2,6,6-tetramethylpiperidin-4-yl) decanedioate Chemical group C1C(C)(C)NC(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)NC(C)(C)C1 XITRBUPOXXBIJN-UHFFFAOYSA-N 0.000 claims description 5
- DXGLGDHPHMLXJC-UHFFFAOYSA-N oxybenzone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1 DXGLGDHPHMLXJC-UHFFFAOYSA-N 0.000 claims description 5
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- OBNCKNCVKJNDBV-UHFFFAOYSA-N butanoic acid ethyl ester Natural products CCCC(=O)OCC OBNCKNCVKJNDBV-UHFFFAOYSA-N 0.000 claims description 4
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- GPNYZBKIGXGYNU-UHFFFAOYSA-N 2-tert-butyl-6-[(3-tert-butyl-5-ethyl-2-hydroxyphenyl)methyl]-4-ethylphenol Chemical compound CC(C)(C)C1=CC(CC)=CC(CC=2C(=C(C=C(CC)C=2)C(C)(C)C)O)=C1O GPNYZBKIGXGYNU-UHFFFAOYSA-N 0.000 claims description 3
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- VKLDCBNUFZIAFK-UHFFFAOYSA-N 1,1-bis[2,4-bis(2-phenylpropan-2-yl)phenyl]-2,2-bis(hydroxymethyl)propane-1,3-diol dihydroxyphosphanyl dihydrogen phosphite Chemical compound OP(O)OP(O)O.C(C)(C)(C1=CC=CC=C1)C1=C(C=CC(=C1)C(C)(C)C1=CC=CC=C1)C(O)(C(CO)(CO)CO)C1=C(C=C(C=C1)C(C)(C)C1=CC=CC=C1)C(C)(C)C1=CC=CC=C1 VKLDCBNUFZIAFK-UHFFFAOYSA-N 0.000 claims description 2
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- XYXJKPCGSGVSBO-UHFFFAOYSA-N 1,3,5-tris[(4-tert-butyl-3-hydroxy-2,6-dimethylphenyl)methyl]-1,3,5-triazinane-2,4,6-trione Chemical compound CC1=CC(C(C)(C)C)=C(O)C(C)=C1CN1C(=O)N(CC=2C(=C(O)C(=CC=2C)C(C)(C)C)C)C(=O)N(CC=2C(=C(O)C(=CC=2C)C(C)(C)C)C)C1=O XYXJKPCGSGVSBO-UHFFFAOYSA-N 0.000 description 4
- FIYMNUNPPYABMU-UHFFFAOYSA-N 2-benzyl-5-chloro-1h-indole Chemical compound C=1C2=CC(Cl)=CC=C2NC=1CC1=CC=CC=C1 FIYMNUNPPYABMU-UHFFFAOYSA-N 0.000 description 4
- HARQWLDROVMFJE-UHFFFAOYSA-N ethyl 3,3-bis(tert-butylperoxy)butanoate Chemical compound CCOC(=O)CC(C)(OOC(C)(C)C)OOC(C)(C)C HARQWLDROVMFJE-UHFFFAOYSA-N 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
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- SYXTYIFRUXOUQP-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy butaneperoxoate Chemical compound CCCC(=O)OOOC(C)(C)C SYXTYIFRUXOUQP-UHFFFAOYSA-N 0.000 description 3
- 230000032683 aging Effects 0.000 description 3
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- 238000004132 cross linking Methods 0.000 description 3
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 3
- DLSMLZRPNPCXGY-UHFFFAOYSA-N tert-butylperoxy 2-ethylhexyl carbonate Chemical compound CCCCC(CC)COC(=O)OOOC(C)(C)C DLSMLZRPNPCXGY-UHFFFAOYSA-N 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Natural products CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
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- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert-Butyl hydroperoxide Substances CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- YEECOJZAMZEUBB-UHFFFAOYSA-N 2,2,3,3,6,6,7,7-octamethyloctane Chemical compound CC(C)(C)C(C)(C)CCC(C)(C)C(C)(C)C YEECOJZAMZEUBB-UHFFFAOYSA-N 0.000 description 1
- WBWXVCMXGYSMQA-UHFFFAOYSA-N 3,9-bis[2,4-bis(2-phenylpropan-2-yl)phenoxy]-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane Chemical compound C=1C=C(OP2OCC3(CO2)COP(OC=2C(=CC(=CC=2)C(C)(C)C=2C=CC=CC=2)C(C)(C)C=2C=CC=CC=2)OC3)C(C(C)(C)C=2C=CC=CC=2)=CC=1C(C)(C)C1=CC=CC=C1 WBWXVCMXGYSMQA-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
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- 125000000218 acetic acid group Chemical group C(C)(=O)* 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
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Abstract
本发明涉及光伏组件加工技术领域,具体涉及一种P型双面电池封装胶膜,包括第一基体树脂、第二基体树脂、抗氧剂、热氧稳定剂、交联剂、光稳定剂和硅烷偶联剂;其中,第一基体树脂为熔融指数范围为5‑18g/10min的PO树脂,第二基体树脂为醋酸乙烯酯(VA)的质量百分含量为23%‑32%的EVA树脂,第一基体树脂与第二基体树脂复配,掺杂比例范围为10%‑90%;抗氧剂含量为0.4%‑2.5%,热氧稳定剂含量为0.4%‑2.7%,交联剂含量为0.5%‑3.3%,光稳定剂含量0.1%‑1.0%,硅烷偶联剂含量为0.1%‑2.1%。该封装胶膜能够克服现有的单纯EVA树脂封装胶膜或PO树脂封装胶膜所具有的缺陷。
Description
技术领域
本发明涉及光伏组件加工技术领域,具体涉及一种P型双面电池封装胶膜。
背景技术
光伏组件使用一段时间后,特别是大型光伏电厂运营几年后,光伏组件会发生电位诱发衰减效应(PID,Potential Induced Degradation),对于PID的引发原因和预防方法的讨论越来越多。目前,抗PID性能已经成为组件的关键技术要求之一。此趋势也使得国内越来越多的光伏电站业主单位、光伏电池和组件厂、测试单位和材料供应商对PID的研究越来越深入。
光伏(PV)产业历经重大变革,光伏转换效率不断提升,价格持续下降。部分地区已达到平价上网,为保持这一趋势,很多厂家在电池片技术方面做了大量的工作,目前开发的双面电池大大提升了组件的发电效率。但双面电池由于铝背场的缺失,以及背面氧化膜结构疏松,对钠,钾离子的阻隔作用大大削弱,导致PID现象比常规单面电池更加严重。
目前太阳能电池组件封装材料主要为EVA(乙烯-醋酸乙烯共聚物)和PO(乙烯-辛烯共聚物),EVA作为太阳能电池长期以来使用的封装材料,具有如下优势:(1)透光率高,组件的起始功率高;(2)工艺适配性好;(3)持久粘结;(4)产品性价比高,且已经有很多年的使用历史,产品开发成熟。但是对于双面电池组件电池自身抗PID性能差,现有的EVA产品不能满足产品使用要求,所以主要用在单面电池的封装。
双面电池的封装主要以PO为主,此款材料的主要优势为:分子结构稳定无醋酸分解,阻隔性好,水汽透过低,长期抗PID效果好。
但是PO作为封装材料由于价格昂贵,提高了组件的成本,并且工艺窗口窄,存在如下问题:
(1)工艺适配:组件生产需要封边胶带及工装夹具,增加生产成本;层压时间长、易出现气泡及片间距不良,导致成品率低。
(2)材料成本:PO胶膜价格是EVA的1.5-2倍,大大提高了组件单瓦成本。
(3)材料缺陷:透光率低(降低了组件的起始功率)、老化过程中产品内应力大,容易引发晶硅电池片隐裂,产品粘结力低、高低温循环易产生结晶、交联速度慢、交联度低以及易产生高温蠕变。
发明内容
为解决现有技术中存在的问题,本发明的目的在于提供一种P型双面电池封装胶膜,该封装胶膜能够克服现有的单纯EVA树脂封装胶膜或PO树脂封装胶膜所具有的缺陷。
本发明的技术方案如下:
一种P型双面电池封装胶膜,由第一基体树脂、第二基体树脂、抗氧剂、热氧稳定剂、交联剂、光稳定剂和硅烷偶联剂混合制成;
封装胶膜中,以质量百分数计,抗氧剂含量为0.4%-2.5%,热氧稳定剂含量为0.4%-2.7%,交联剂含量为0.5%-3.3%,光稳定剂含量0.1%-1.0%,硅烷偶联剂含量为0.1%-2.1%,其余为第一基体树脂和第二基体树脂的复配物;
第一基体树脂为熔融指数范围为5-18g/10min的PO树脂,第二基体树脂为醋酸乙烯酯(VA)的质量百分含量为23%-32%的EVA树脂,第一基体树脂与第二基体树脂复配,且形成的复配物中第一基体树脂与第二基体树脂的掺杂比例范围为10%-90%。
第一基体树脂与第二基体树脂复配方式为共混掺杂后挤出成膜。
第一基体树脂与第二基体树脂复配方式包括:
一种熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同醋酸乙烯酯含量的第二基体树脂与一种熔融指数的第一基体树脂共混。
所述第一基体树脂中,辛烯的质量百分含量为20%~30%,透光率>85%。
所述第二基体树脂的透光率>90%。
抗氧剂为主剂与辅剂复配而成的体系,主剂为3,5-二叔丁基-4-羟基苄基膦酸双十八酯、双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯、三(4-壬基酚)亚磷酸酯、亚磷酸三(2,4-二叔丁基苯基)酯或2,2’-亚甲基-双-(4-乙基-6-叔丁基苯酚);
辅剂为1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、三(2,4-二叔丁基苯基)亚磷酸酯或二(2,4-二枯基苯基)季戊四醇二亚磷酸酯,封装胶膜中,以质量百分数计,主剂的含量为0.3%-2.0%,辅剂的含量为0.1%-0.8%。
所述光稳定剂为双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、2-羟基-4-甲氧基二苯甲酮或2-羟基-4-正辛氧基二苯甲酮。
所述交联剂为有机过氧化物或偶氮化合物。
所述交联剂为2,5-二甲基-2,5二叔丁基过氧化己烷,4,4-二(叔戊基过氧)戊酸正丁基酯,过氧化2-乙基己基碳酸叔丁酯和3,3-二(叔丁基过氧)丁酸乙酯中的至少一种。
所述热氧稳定剂为复合稳定剂。
所述热氧稳定剂为二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合而成的复合热稳定剂,封装胶膜中,以质量百分数计,二月桂酸二正辛基锡的含量为0.3%-2.0%,聚乙二醇二月桂酸酯的含量为0.1%-1.0%。
所述硅烷偶联剂为乙烯基三过氧化叔丁基硅烷,乙烯基三乙酰氧基硅烷和乙烯基三(β-甲氧基乙氧基)硅烷中的至少一种。
与现有技术相比,本发明具有如下有益效果:
本发明的P型双面电池封装胶膜通过将第一基体树脂与第二基体树脂复配,且形成的复配物中第一基体树脂与第二基体树脂的掺杂比例范围为10%-90%,第一基体树脂为熔融指数范围为5-18g/10min的PO树脂,第二基体树脂为醋酸乙烯酯(VA)的质量百分含量为23%-32%的EVA树脂,通过将第一基体树脂与第二基体树脂共混,既能够保证成膜的均匀性又能够保证材料的高透光率,增加双面电池对光的利用率,能还够提高组件起始功率,提高了组件端1-2%的功率增益;
通过第一基体树脂与第二基体树脂的共混,克服了单纯PO树脂粒子交联度不高,容易产生高温蠕变,以及层压工艺窗口窄的问题,能够提高产品良率;还克服了单纯EVA树脂阻水性能差,容易水解产生醋酸根(-COOH),加重双面电池的PID失效得缺陷;能够降低P型双面电池封装材料的使用成本;能够克服PO树脂粒子内聚能大,长期老化过程中容易出现电池片的隐裂,以及粘结力差的问题。
具体实施方式
下面结合实施例来对本发明作进一步的说明。
本发明的P型双面电池封装胶膜由第一基体树脂、第二基体树脂、抗氧剂、热氧稳定剂、交联剂、光稳定剂和硅烷偶联剂混合制成;
封装胶膜中,以质量百分数计,抗氧剂含量为0.4%-2.5%,热氧稳定剂含量为0.4%-2.7%,交联剂含量为0.5%-3.3%,光稳定剂含量0.1%-1.0%,硅烷偶联剂含量为0.1%-2.1%,其余为第一基体树脂和第二基体树脂;
第一基体树脂为熔融指数范围为5-18g/10min的PO树脂,辛烯的质量百分含量为20%~30%,透光率>85%;第二基体树脂为醋酸乙烯酯(VA)的质量百分含量为23%-32%的EVA树脂,透光率>90%;第一基体树脂与第二基体树脂复配,复配方式为共混掺杂后挤出成膜,且形成的复配物中第一基体树脂与第二基体树脂的掺杂比例范围为10%-90%。
本发明中:第一基体树脂与第二基体树脂复配方式包括:
一种熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同醋酸乙烯酯含量的第二基体树脂与一种熔融指数的第一基体树脂共混。
抗氧剂为主剂与辅剂复配而成的体系,主剂为3,5-二叔丁基-4-羟基苄基膦酸双十八酯、双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯、三(4-壬基酚)亚磷酸酯、亚磷酸三(2,4-二叔丁基苯基)酯或2,2’-亚甲基-双-(4-乙基-6-叔丁基苯酚);
辅剂为1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、三(2,4-二叔丁基苯基)亚磷酸酯或二(2,4-二枯基苯基)季戊四醇二亚磷酸酯,封装胶膜中,以质量百分数计,主剂的含量为0.3%-2.0%,辅剂的含量为0.1%-0.8%。
光稳定剂为双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、2-羟基-4-甲氧基二苯甲酮或2-羟基-4-正辛氧基二苯甲酮。
交联剂为有机过氧化物或偶氮化合物,具体为2,5-二甲基-2,5二叔丁基过氧化己烷,4,4-二(叔戊基过氧)戊酸正丁基酯,过氧化2-乙基己基碳酸叔丁酯、3,3-二(叔丁基过氧)丁酸乙酯中的至少一种。
热氧稳定剂为复合稳定剂,为二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物,封装胶膜中,以质量百分数计,二月桂酸二正辛基锡的含量为0.3%-2.0%,聚乙二醇二月桂酸酯的含量为0.1%-1.0%。
硅烷偶联剂为乙烯基三过氧化叔丁基硅烷,乙烯基三乙酰氧基硅烷,乙烯基三(β-甲氧基乙氧基)硅烷中的至少一种。
实施例1
本实施例的P型双面电池封装胶膜包括熔融指数范围为5g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为25%的EVA树脂、3,5-二叔丁基-4-羟基苄基膦酸双十八酯、1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、2,5-二甲基-2,5二叔丁基过氧化己烷、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯和乙烯基三乙酰氧基硅烷;
其中,PO树脂的辛烯的质量百分含量为20%,透光率>85%;EVA树脂透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,复配物中PO树脂的质量百分含量为10%,其余为EVA树脂;
封装胶膜中,以质量百分数计,抗氧剂含量为0.4%:主剂3,5-二叔丁基-4-羟基苄基膦酸双十八酯的含量为0.3%,辅剂1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮的含量为0.1%;
热氧稳定剂含量为0.4%:二月桂酸二正辛基锡的含量为0.3%,聚乙二醇二月桂酸酯的含量为0.1%;
交联剂2,5-二甲基-2,5二叔丁基过氧化己烷的含量为0.5%;
光稳定剂双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯的含量0.1%;
硅烷偶联剂乙烯基三乙酰氧基硅烷的含量为0.1%。
实施例2
本实施例的P型双面电池封装胶膜包括熔融指数范围为18g/10min的PO树脂、熔融指数范围为12g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为32%的EVA树脂、双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯、1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、2,5-二甲基-2,5二叔丁基过氧化己烷、3,3-二(叔丁基过氧)丁酸乙酯、2-羟基-4-甲氧基二苯甲酮、乙烯基三乙酰氧基硅烷和乙烯基三(β-甲氧基乙氧基)硅烷;
其中,PO树脂的辛烯的质量百分含量为25%,透光率>85%;EVA树脂的透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,残杂物中熔融指数范围为18g/10min的PO树脂的质量百分含量为20%,熔融指数范围为12g/10min的PO树脂的质量百分含量为20%,其余为EVA树脂;
封装胶膜中,以质量百分数计,抗氧剂含量为1.8%:主剂双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯的含量为1,0%,辅剂1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮的含量为0.8%;
热氧稳定剂含量为2.0%:二月桂酸二正辛基锡的含量为1.5%,聚乙二醇二月桂酸酯的含量为0.5%;
交联剂含量为2.5%:2,5-二甲基-2,5二叔丁基过氧化己烷的含量为1.5%,3,3-二(叔丁基过氧)丁酸乙酯含量为1.0%;
光稳定剂2-羟基-4-甲氧基二苯甲酮的含量为0.8%;
硅烷偶联剂含量为1.5%:乙烯基三乙酰氧基硅烷的含量为0.8%,乙烯基三(β-甲氧基乙氧基)硅烷的含量为0.7%。
实施例3
本实施例的P型双面电池封装胶膜包括熔融指数范围为8g/10min的PO树脂、熔融指数范围为15g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为23%的EVA树脂、醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂、三(4-壬基酚)亚磷酸酯、三(2,4-二叔丁基苯基)亚磷酸酯、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、4,4-二(叔戊基过氧)戊酸正丁基酯、过氧化2-乙基己基碳酸叔丁酯、3,3-二(叔丁基过氧)丁酸乙酯、2-羟基-4-正辛氧基二苯甲酮和乙烯基三(β-甲氧基乙氧基)硅烷;
其中,PO树脂辛烯的质量百分含量为30%,透光率>85%;EVA树脂的透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,复配物中熔融指数范围为8g/10min的PO树脂的质量百分含量为35%,熔融指数范围为15g/10min的PO树脂的质量百分含量为35%,醋酸乙烯酯(VA)的质量百分含量为23%的EVA树脂的质量百分含量为15%,醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂的质量百分含量为15%;
封装胶膜中,以质量百分数计,抗氧剂含量为2.5%:主剂三(4-壬基酚)亚磷酸酯的含量为2.0%,辅剂三(2,4-二叔丁基苯基)亚磷酸酯的含量为0.5%;
热氧稳定剂含量为2.7%:二月桂酸二正辛基锡的含量为1.5%,聚乙二醇二月桂酸酯的含量为1.2%;
交联剂含量为1.8%:4,4-二(叔戊基过氧)戊酸正丁基酯含量为1.0%,过氧化2-乙基己基碳酸叔丁酯含量为0.4%,3,3-二(叔丁基过氧)丁酸乙酯含量为0.4%;
光稳定剂2-羟基-4-正辛氧基二苯甲酮的含量为0.5%;
硅烷偶联剂乙烯基三(β-甲氧基乙氧基)硅烷的含量为1.0%。
实施例4
本实施例的P型双面电池封装胶膜包括熔融指数范围为15g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为30%的EVA树脂、醋酸乙烯酯(VA)的质量百分含量为25%的EVA树脂、三(4-壬基酚)亚磷酸酯、三(2,4-二叔丁基苯基)亚磷酸酯、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、4,4-二(叔戊基过氧)戊酸正丁基酯、过氧化2-乙基己基碳酸叔丁酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、乙烯基三过氧化叔丁基硅烷、乙烯基三乙酰氧基硅烷、乙烯基三(β-甲氧基乙氧基)硅烷和3,3-二(叔丁基过氧)丁酸乙酯;
其中,PO树脂的辛烯的质量百分含量为28%,透光率>85%;EVA树脂的透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,复配物中PO树脂的质量百分含量为90%,醋酸乙烯酯(VA)的质量百分含量为30%的EVA树脂的质量百分含量为5%,醋酸乙烯酯(VA)的质量百分含量为25%的EVA树脂的质量百分含量为5%;
封装胶膜中,以质量百分数计,抗氧剂含量为2.5%:主剂三(4-壬基酚)亚磷酸酯的含量为2.0%,辅剂三(2,4-二叔丁基苯基)亚磷酸酯的含量为0.5%;
热氧稳定剂含量为2.7%:二月桂酸二正辛基锡的含量为1.5%,聚乙二醇二月桂酸酯的含量为1.2%;
交联剂含量为1.8%:4,4-二(叔戊基过氧)戊酸正丁基酯含量为1.0%,过氧化2-乙基己基碳酸叔丁酯含量为0.4%,3,3-二(叔丁基过氧)丁酸乙酯含量为0.4%;
光稳定剂2-羟基-4-正辛氧基二苯甲酮的含量为0.5%;
硅烷偶联剂乙烯基三(β-甲氧基乙氧基)硅烷的含量为1.0%。
实施例5
本实施例的P型双面电池封装胶膜包括熔融指数范围为11g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂、醋酸乙烯酯(VA)的质量百分含量为32%的EVA树脂、3,5-二叔丁基-4-羟基苄基膦酸双十八酯、1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、2,5-二甲基-2,5二叔丁基过氧化己烷、4,4-二(叔戊基过氧)戊酸正丁基酯、过氧化2-乙基己基碳酸叔丁酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、乙烯基三过氧化叔丁基硅烷、乙烯基三乙酰氧基硅烷和乙烯基三(β-甲氧基乙氧基)硅烷;
其中,PO树脂的辛烯的质量百分含量为22%,透光率>85%;EVA树脂的透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,复配物中PO树脂的质量百分含量为80%,醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂的质量百分含量为10%,醋酸乙烯酯(VA)的质量百分含量为32%的EVA树脂的质量百分含量为10%;
封装胶膜中,以质量百分数计,抗氧剂含量为1.0%:主剂3,5-二叔丁基-4-羟基苄基膦酸双十八酯的含量为0.8%,辅剂三1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮的含量为0.2%;
热氧稳定剂含量为1.5%:二月桂酸二正辛基锡的含量为0.5%,聚乙二醇二月桂酸酯的含量为1.0%;
交联剂含量为3.3%:2,5-二甲基-2,5二叔丁基过氧化己烷的含量为1.0%,4,4-二(叔戊基过氧)戊酸正丁基酯的含量为1.5%,过氧化2-乙基己基碳酸叔丁酯的含量为0.4%,3,3-二(叔丁基过氧)丁酸乙酯的含量为0.4%;
光稳定剂丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物的含量为1.0%;
硅烷偶联剂的含量为2.1%:乙烯基三过氧化叔丁基硅烷的含量为1.0%,乙烯基三乙酰氧基硅烷的含量为0.5%,乙烯基三(β-甲氧基乙氧基)硅烷的含量为0.6%。
实施例6
本实施例的P型双面电池封装胶膜包括熔融指数范围为11g/10min的PO树脂、醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂、醋酸乙烯酯(VA)的质量百分含量为32%的EVA树脂、双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯、二(2,4-二枯基苯基)季戊四醇二亚磷酸酯、二月桂酸二正辛基锡和聚乙二醇二月桂酸酯的混合物、2,5-二甲基-2,5二叔丁基过氧化己烷、4,4-二(叔戊基过氧)戊酸正丁基酯、过氧化2-乙基己基碳酸叔丁酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、乙烯基三过氧化叔丁基硅烷、乙烯基三乙酰氧基硅烷和乙烯基三(β-甲氧基乙氧基)硅烷;
其中,PO树脂的辛烯的质量百分含量为22%,透光率>85%;EVA树脂的透光率>90%;PO树脂与EVA树脂复配,复配方式为共混掺杂后挤出成膜,复配物中PO树脂的质量百分含量为80%,醋酸乙烯酯(VA)的质量百分含量为28%的EVA树脂的质量百分含量为10%,醋酸乙烯酯(VA)的质量百分含量为32%的EVA树脂的质量百分含量为10%;
封装胶膜中,以质量百分数计,抗氧剂含量为1.0%:主剂双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯的含量为0.8%,辅剂二(2,4-二枯基苯基)季戊四醇二亚磷酸酯的含量为0.2%;
热氧稳定剂含量为1.5%:二月桂酸二正辛基锡的含量为0.5%,聚乙二醇二月桂酸酯的含量为1.0%;
交联剂含量为3.3%:2,5-二甲基-2,5二叔丁基过氧化己烷的含量为1.0%,4,4-二(叔戊基过氧)戊酸正丁基酯的含量为1.5%,过氧化2-乙基己基碳酸叔丁酯的含量为0.4%,3,3-二(叔丁基过氧)丁酸乙酯的含量为0.4%;
光稳定剂丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物的含量为1.0%;
硅烷偶联剂的含量为2.1%:乙烯基三过氧化叔丁基硅烷的含量为1.0%,乙烯基三乙酰氧基硅烷的含量为0.5%,乙烯基三(β-甲氧基乙氧基)硅烷的含量为0.6%。
表1为本发明各实施例制备的封装胶膜,以及对比例封装胶膜的PID测试结果:
表1
表1中,PID测试条件:1500V,192h;PID前IV表示:初始测试数据;PID后IV表示:PID测试后数据。
表1中:从测试结果看,实施例1-6均能满足抗PID的效果,相对于纯PO及EVA抗PID性能均有所改善,其中,对比实施例1为纯PO的PID测试结果,此款纯PO为目前市场上的常规产品,产品型号为TF4,对比实施例2为纯EVA的PID测试结果,此款纯EVA为目前市场上常规产品,产品型号为S201,综上,实施例1更能满足产线适配性。
表2为本发明各实施例制备的封装胶膜的性能参数:
表2
从各项性能测试结果看,实施例1-6均满足产品使用要求,实例1在透光率与粘结力具有更大的优势。
本发明提供的制造方法及配方设计,制得的P型双面电池用胶膜的透明性和耐老化性能得到了很大的提高,提高了太阳能电池组件的使用寿命,提升了P型双面电池的效率,满足产品抗PID使用要求。
Claims (6)
1.一种P型双面电池封装胶膜,其特征在于,由第一基体树脂、第二基体树脂、抗氧剂、热氧稳定剂、交联剂、光稳定剂和硅烷偶联剂混合制成;
封装胶膜中,以质量百分数计,抗氧剂含量为0.4%-2.5%,热氧稳定剂含量为0.4%-2.7%,交联剂含量为0.5%-3.3%,光稳定剂含量为0.1%-1.0%,硅烷偶联剂含量为0.1%-2.1%,其余为第一基体树脂和第二基体树脂的复配物;
第一基体树脂为熔融指数范围为5-18g/10min的PO树脂,第二基体树脂为醋酸乙烯酯的质量百分含量为23%-32%的EVA树脂,第一基体树脂与第二基体树脂复配,且形成的复配物中第一基体树脂与第二基体树脂的掺杂比例范围为10%-90%;
抗氧剂为主剂与辅剂复配而成的体系,主剂为3,5-二叔丁基-4-羟基苄基膦酸双十八酯、双十八烷基-4-叔丁基-3-羟基-2,6-二甲基苄基膦酸酯、三(4-壬基酚)亚磷酸酯、亚磷酸三(2,4-二叔丁基苯基)酯或2,2’-亚甲基-双-(4-乙基-6-叔丁基苯酚);
辅剂为1,3,5-三(4-叔丁基-3-羟基-2,6-二甲基苯甲基)-1,3,5-三嗪-2,4,6-(1H,3H,5H)-三酮、三(2,4-二叔丁基苯基)亚磷酸酯或二(2,4-二枯基苯基)季戊四醇二亚磷酸酯;
封装胶膜中,以质量百分数计,主剂的含量为0.3%-2.0%,辅剂的含量为0.1%-0.8%;
所述交联剂为2,5-二甲基-2,5二叔丁基过氧化己烷,4,4-二(叔戊基过氧)戊酸正丁基酯,过氧化2-乙基己基碳酸叔丁酯和3,3-二(叔丁基过氧)丁酸乙酯中的至少一种;
所述第一基体树脂中,辛烯的质量百分含量为20%~30%,透光率>85%,所述第二基体树脂的透光率>90%。
2.根据权利要求1所述的一种P型双面电池封装胶膜,其特征在于,第一基体树脂与第二基体树脂复配方式为共混掺杂后挤出成膜。
3.根据权利要求1所述的一种P型双面电池封装胶膜,其特征在于,第一基体树脂与第二基体树脂复配方式包括:
一种熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同熔融指数的第一基体树脂与一种醋酸乙烯酯含量的第二基体树脂共混,两种不同醋酸乙烯酯含量的第二基体树脂与一种熔融指数的第一基体树脂共混。
4.根据权利要求1所述的一种P型双面电池封装胶膜,其特征在于,所述光稳定剂为双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、丁二酸与4-羟基-2,2,6,6-四甲基-1-哌啶乙醇的聚合物、2-羟基-4-甲氧基二苯甲酮或2-羟基-4-正辛氧基二苯甲酮。
5.根据权利要求1所述的一种P型双面电池封装胶膜,其特征在于,所述热氧稳定剂为二月桂酸二正辛基锡和聚乙二醇二月桂酸酯混合而成的复合热稳定剂,封装胶膜中,以质量百分数计,二月桂酸二正辛基锡的含量为0.3%-2.0%,聚乙二醇二月桂酸酯的含量为0.1%-1.0%。
6.根据权利要求1所述的一种P型双面电池封装胶膜,其特征在于,所述硅烷偶联剂为乙烯基三过氧化叔丁基硅烷,乙烯基三乙酰氧基硅烷和乙烯基三(β-甲氧基乙氧基)硅烷中的至少一种。
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