CN108215402A - 无卤光伏背板及其制备方法 - Google Patents
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Abstract
本发明涉及一种无卤光伏背板，其主要特点是，所述的背板依次包括第一丙烯酸酯层，第一改性PET层，白色PET层，第二改性PET层，第二丙烯酸酯层，所述的改性PET层的原料包括PET、稳定剂和封端剂。本发明还提供了一种无卤光伏背板的制备方法。采用了该发明中的无卤光伏背板，包含抗水解改性PET层，机械性能强，耐老化性能优异，对比传统含氟背板，不仅反射率高，阻水性好而且环境友好，成本低廉。
Description
技术领域
本发明涉及复合材料技术领域，尤其涉及光伏背板，具体是指一种无卤光伏背板。
背景技术
太阳能背板分为含氟背板与不含氟背板两大类。其中，含氟背板又分为双面含氟与单面含氟两种；不含氟的背板多通过胶粘剂将PE，PET或其改性材料等复合粘接而成。目前主流背板都具有叠层结构，一般是由几种高分子材料复合而成，但是这种复合结构会导致制备的太阳能电池背板涂层面上有波形，层与层之间粘接性不稳定。
太阳能背板位于太阳能电池片的背面，对电池片起保护和支撑作用，需要具备卓越的耐长期老化性能(紫外，湿热，干热等)、耐电气绝缘性能，水蒸气阻隔性能。含氟背板耐候性能优异，被大量用来制备太阳能电池背板的耐候层，但是氟塑料成本高昂，环境不友好，大大限制了其发展空间。
传统的背板中通常用PET层作为耐候层，PET主链含有大量的酯基，在湿热条件下容易发生水解。湿热老化初期水分在PET表面吸附，缓慢渗透，由于随着时间延长，水对PET的刻蚀和溶剂化作用，PET的结晶度逐渐升高，其表面微孔和龟裂增加，与此同时PET分子链中酯键受到水分子攻击而发生断裂，形成分子链更短的PET，在水增速的作用下结晶度进一步增加，PET脆性增加，水分向PET内部渗透加速，以上过程不断重复，最终使PET失去原有的力学性能和水气阻隔性能。而温度的升高，一方面加速PET结晶，从而增加其龟裂程度；另外还增加了端羧基的活泼性，加速水解反应的发生。
因此，如何寻找一种不含氟塑料的耐候性背板一直是本行业的研究重点。
发明内容
本发明的目的是克服了上述现有技术的缺点，提供了一种具有机械性能强、耐老化性能优异、反射率高、阻水性好而且环境友好、成本低廉的改性PET层的无卤光伏背板。
为了实现上述目的，本发明的无卤光伏背板，其主要特点是，
所述的背板依次包括第一丙烯酸酯层，第一改性PET层，白色PET层，第二改性PET层，第二丙烯酸酯层，所述的改性PET层的原料包括PET、稳定剂和封端剂。
较佳地，所述的封端剂包括噁唑啉化合物、异氰酸酯齐聚物、碳化二亚胺或环氧化合物中的一种或多种。
更佳地，所述的噁唑啉化合物包括2-乙基-2-噁唑啉，二噁唑啉中的一种或两种，所述的异氰酸酯齐聚物包括甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、苯二亚甲基二异氰酸酯、二环已基甲烷二异氰酸酯、已二异氰酸酯、异佛尔酮二异氰酸酯中的一种或多种，所述的环氧化合物包括丁基环氧丙基醚、苯基环氧丙基醚或甲苯基环氧丙基醚中的一种或多种。
较佳地，所述的稳定剂包括抗氧剂、光稳定剂、紫外吸收剂或抗热氧老化分解剂中的一种或多种。
较佳地，所述的改性PET层的原料质量比包括：97.0％～99.0％的PET、0.1％～0.5％的稳定剂和0.1％～3.0％的封端剂。
较佳地，所述的白色PET层中包括无机白色填料，所述的无机白色填料为钛白粉或硫酸钡，所述的丙烯酸酯层包括羟基丙烯酸酯、环氧丙烯酸酯、羧基丙烯酸酯、N-羟甲基丙烯酰胺、硅氧烷基丙烯酸酯中的一种或多种。
较佳地，所述的背板包括的各层的厚度范围依次为：所述的第一丙烯酸酯层厚度为0.1～5微米，第一改性PET层厚度为20～80微米，白色PET层厚度为60～300微米，第二改性PET层厚度为20～80微米，第二丙烯酸酯层厚度为0.1～5微米。
较佳地，所述的背板的厚度为220～400微米。
本发明还提供了一种所述的无卤光伏背板的制备方法，其特征在于，所述的制备方法包括以下步骤：
步骤(1)：将PET、稳定剂和封端剂混合，经挤出机造粒，制得改性PET粒料；
步骤(2)：将改性PET粒料和白色PET粒料通过ABA型挤出机三层共挤成型，制得依次包括第一改性PET层、白色PET层、第二改性PET层的层叠体；
步骤(3)：将所述的层叠体进行双面电晕，涂覆丙烯酸酯于所述的层叠体的两侧面上，制得无卤光伏背板。
采用了该发明中的无卤光伏背板及其制备方法，包含抗水解改性PET层，机械性能强，耐老化性能优异，对比传统含氟背板，不仅反射率高，阻水性好而且环境友好，成本低廉。
附图说明
图1为本发明的无卤光伏背板的结构示意图。
附图标记
1 白色PET层
2 第一改性PET层
3 第二改性PET层
4 第一丙烯酸酯层
5 第二丙烯酸酯层
具体实施方式
为了能够更清楚地描述本发明的技术内容，下面结合具体实施例来进行进一步的描述。
如图1所示，本发明提供一种不含卤素的光伏背板，该无卤光伏背板依次包括第一丙烯4酸酯层，第一改性PET层2，白色PET层1，第二改性PET层3，第二丙烯酸酯层5，所述的改性PET层的原料包括PET、稳定剂和封端剂。第一改性PET层和第二改性PET层由封端剂和稳定剂改性聚对苯二甲酸乙二醇酯(PET)制备而成，封端剂可以为环氧化合物，异氰酸酯齐聚物，碳化二亚胺，噁唑啉化合物中的一种或几种。
所述噁唑啉化合物包括但不限于2-乙基-2-噁唑啉，二噁唑啉中的一种或多种。所述异氰酸酯齐聚物包括但不限于甲苯二异氰酸酯，二苯基甲烷二异氰酸酯，苯二亚甲基二异氰酸酯，二环已基甲烷二异氰酸酯，已二异氰酸酯，异佛尔酮二异氰酸酯中的一种或多种。所述环氧化合物包括但不限于丁基环氧丙基醚，苯基环氧丙基醚和甲苯基环氧丙基醚中的一种或多种。
所述的稳定剂包括抗氧剂、光稳定剂、紫外吸收剂或抗热氧老化分解剂中的一种或多种，其可以但不限于酚类抗氧剂、受阻胺类抗氧剂、亚磷酸类、苯甲酮类、苯并三唑类，例如：不限于四[β-(3，5-二叔丁基-4-羟基苯基)丙酸]季戊四醇酯、癸二酸二(2,2,6,6-四甲基-4-哌啶)酯和N,N'-二仲丁基对苯二胺的一种或几种。
实施例1
本实施例中使用的封端剂为异氰酸酯齐聚物，第一改性PET层和第二改性PET层的具体组分含量如下：
聚对苯二甲酸乙二醇酯99％，抗氧剂0.1％，光稳定剂0.1％，异氰酸酯齐聚物0.2％。
白色PET层由无机白色填料和热稳定剂共混的普通聚对苯二甲酸乙二醇酯制备而成，所述无机白色填料为钛白粉或硫酸钡。在本实施例中，无机白色填料为钛白粉，白色PET层的具体组分含量如下：
聚对苯二甲酸乙二醇酯78％，抗氧剂0.1％，光稳定剂0.1％，钛白粉22％。
无卤光伏背板的制备方法包括如下步骤：
(1)、第一改性PET层、第二改性PET层和白色PET层的原材料分别经过挤出机造粒，得到第一改性PET层、第二改性PET层和白色PET层的粒子备用；
(2)、将步骤(1)准备的第一改性PET层、第二改性PET层和白色PET层粒子通过ABA型挤出机三层共挤成型，形成层叠体。
(3)、将步骤(2)得到的三层PET材料层叠体进行双面电晕，涂覆第一丙烯酸酯层和第二丙烯酸酯层。
在该实施例中，第一改性PET层的厚度为30微米，白色PET层的厚度为240微米，第二改性PET层的厚度为30微米，第一丙烯酸酯层的厚度为4微米，第二丙烯酸酯层的厚度为4微米。
本发明产品与国内同类型其他产品相比，各项参数如下表：
| 性能 | 单位 | 国内产品1 | 国内产品2 | 本发明专利 |
| 表面张力 | mN/cm | 32 | 35 | >60 |
| 对EVA粘接力 | N/cm | 40 | 52 | 70 |
| 水汽透过率 | g/m2*d | 4.8 | 3.9 | <3 |
| 反光率 | ％ | 89 | 90 | 92 |
实施例2
本实施例中使用的封端剂为噁唑啉化合物和碳化二亚胺，第一改性PET层和第二改性PET层的具体组分含量如下：
聚对苯二甲酸乙二醇酯97％，抗氧剂0.1％，光稳定剂0.1％，噁唑啉化合物1％，碳化二亚胺2％。
白色PET层及无卤光伏背板的制备方法与实施例1相同。
在该实施例中，第一改性PET层的厚度为40微米，白色PET层的厚度为240微米，第二改性PET层的厚度为40微米，第一丙烯酸酯层的厚度为5微米，第二丙烯酸酯层的厚度为5微米。
本发明产品与国内同类型其他产品相比，各项参数如下表：
| 性能 | 单位 | 国内产品1 | 国内产品2 | 本发明专利 |
| 表面张力 | mN/cm | 32 | 35 | >50 |
| 对EVA粘接力 | N/cm | 40 | 52 | 65 |
| 水汽透过率 | g/m2*d | 4.8 | 3.9 | 3.5 |
| 反光率 | ％ | 89 | 90 | 92 |
实施例3
本实施例中使用的封端剂为碳化二亚胺和环氧化合物，第一改性PET层和第二改性PET层的具体组分含量如下：
聚对苯二甲酸乙二醇酯97％，抗氧剂0.1％，光稳定剂0.1％，碳化二亚胺3％，环氧化合物物0.02％。
白色PET层及无卤光伏背板的制备方法与实施例1相同。
在该实施例中，第一改性PET层的厚度为30微米，白色PET层的厚度为300微米，第二改性PET层的厚度为30微米，第一丙烯酸酯层的厚度为4微米，第二丙烯酸酯层的厚度为4微米。
本发明产品与国内同类型其他产品相比，各项参数如下表：
| 性能 | 单位 | 国内产品1 | 国内产品2 | 本发明专利 |
| 表面张力 | mN/cm | 32 | 35 | >50 |
| 对EVA粘接力 | N/cm | 40 | 52 | 68 |
| 水汽透过率 | g/m2*d | 4.8 | 3.9 | <3 |
| 反光率 | ％ | 89 | 90 | 92 |
采用了该发明中的无卤光伏背板，包含抗水解改性PET层，机械性能强，耐老化性能优异，对比传统含氟背板，不仅反射率高，阻水性好而且环境友好，成本低廉。
在此说明书中，本发明已参照其特定的实施例作了描述。但是，很显然仍可以作出各种修改和变换而不背离本发明的精神和范围。因此，说明书和附图应被认为是说明性的而非限制性的。
Claims (9)
1.一种无卤光伏背板，其特征在于，所述的背板依次包括第一丙烯酸酯层，第一改性PET层，白色PET层，第二改性PET层，第二丙烯酸酯层，所述的改性PET层的原料包括PET、稳定剂和封端剂。
2.根据权利要求1所述的无卤光伏背板，其特征在于，所述的封端剂包括噁唑啉化合物、异氰酸酯齐聚物、碳化二亚胺或环氧化合物中的一种或多种。
3.根据权利要求2所述的无卤光伏背板，其特征在于，所述的噁唑啉化合物包括2-乙基-2-噁唑啉，二噁唑啉中的一种或两种，所述的异氰酸酯齐聚物包括甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、苯二亚甲基二异氰酸酯、二环已基甲烷二异氰酸酯、已二异氰酸酯、异佛尔酮二异氰酸酯中的一种或多种，所述的环氧化合物包括丁基环氧丙基醚、苯基环氧丙基醚或甲苯基环氧丙基醚中的一种或多种。
4.根据权利要求1所述的无卤光伏背板，其特征在于，所述的稳定剂包括抗氧剂、光稳定剂、紫外吸收剂或抗热氧老化分解剂中的一种或多种。
5.根据权利要求1所述的无卤光伏背板，其特征在于，所述的改性PET层的原料质量比包括：97.0％～99.0％的PET、0.1％～0.5％的稳定剂和0.1％～3.0％的封端剂。
6.根据权利要求1所述的无卤光伏背板，其特征在于，所述的白色PET层中包括无机白色填料，所述的无机白色填料为钛白粉或硫酸钡，所述的丙烯酸酯层包括羟基丙烯酸酯、环氧丙烯酸酯、羧基丙烯酸酯、N-羟甲基丙烯酰胺、硅氧烷基丙烯酸酯中的一种或多种。
7.根据权利要求1所述的无卤光伏背板，其特征在于，所述的背板包括的各层的厚度范围依次为：所述的第一丙烯酸酯层厚度为0.1～5微米，第一改性PET层厚度为20～80微米，白色PET层厚度为60～300微米，第二改性PET层厚度为20～80微米，第二丙烯酸酯层厚度为0.1～5微米。
8.根据权利要求1所述的无卤光伏背板，其特征在于，所述的背板的厚度为220～400微米。
9.一种根据权利要求1至8中任一项所述的无卤光伏背板的制备方法，其特征在于，所述的制备方法包括以下步骤：
步骤(1)：将PET、稳定剂和封端剂混合，经挤出机造粒，制得改性PET粒料；
步骤(2)：将改性PET粒料和白色PET粒料通过ABA型挤出机三层共挤成型，制得依次包括第一改性PET层、白色PET层、第二改性PET层的层叠体；
步骤(3)：将所述的层叠体进行双面电晕，涂覆丙烯酸酯于所述的层叠体的两侧面上，制得无卤光伏背板。
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