CN108440778A - 一种用于光伏组件隔离条及其生产方法 - Google Patents
一种用于光伏组件隔离条及其生产方法 Download PDFInfo
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Abstract
一种用于光伏组件隔离条,其特征在于:自上而下,第一层为改性PE/EVA层,第二层为EVA胶粘层,第三层为PET层,第四层为EVA胶粘层和第五层为改性PMMA/EVA层。通过采用上述技术方案,首先将改性PE/EVA层作为第一层,在使用时,使其直接暴露在了阳光下,由于PE具有一定的抗UV的能量,从而改性PE/EVA层也就为其他层提供了保护。而将改性PMMA/EVA层作为最后层,由于PMMA的抗UV能力比较的强,从而也有效地增强了整体隔离条的抗UV作用。且其生产方法整体又比较简单,并且隔离条也通过多次UV固化和臭氧处理过,从而加快了其生产效率,以及之后使用的稳定性,因而适合大范围推广。
Description
技术领域
本发明涉及光伏领域,特别涉及一种用于光伏组件隔离条及其生产方法。
背景技术
能源与环境是21世纪人类面临的两大基本问题。发展无污染、可再生的新能源是解决这两大问题的必由之路。目前,光伏发电在能源中所占比重极小,成本过高是制约光伏发电大规模应用的主要障碍。开发新一代高效率、低成本的太阳电池组件,使其发电成本接近甚至低于常规能源,这已成为重中之重的问题。
目前在太阳能电池封装中,电池正负极在模组边缘汇流条处需要使用隔离条进行正负极的绝缘隔离,此隔离条需要有良好的电绝缘和稳定性(耐紫外老化性),同时需要能与EVA(醋酸乙烯酯共聚物)、电池片、焊带保持长期稳定的粘结,目前通常使用EVA和背板材料对组件汇流条进行隔离,放置隔离条时操作步骤复杂,导致生产效率降低、制造成本增加。而且,目前市面上通常使用的隔离条有背板材料型与EVA型隔离条两种,背板材料隔离条成本太高,EVA型隔离条耐紫外性较差。
同时,太阳能光伏电池模组需要在室外吸收太阳光照,在长时间紫外线的照射下,太阳能光伏电池模组的光电转换效率会很快下降,现有组件耐UV紫外性能差,从而失去实用价值,因此需要隔离条对紫外线照射有较强的抵抗作用。
因此,如何提供一种成本低廉,耐UV紫外性能优异,同时粘结强度高的隔离条,成为了业界亟待解决的难题。
发明内容
本发明的目的在于提供一种用于光伏组件的隔离条,该种隔离条具有良好的抗UV的性能,并且其整个生产方法也比较的简单,适合大规模生产。
本发明的上述目的是通过以下技术方案得以实现的:一种用于光伏组件隔离条,其特征在于:自上而下,第一层为改性PE/EVA层,第二层为EVA胶粘层,第三层为PET层,第四层为EVA胶粘层和第五层为改性PMMA/EVA层。
通过采用上述技术方案,首先将改性PE/EVA层作为第一层,在使用时,使其直接暴露在了阳光下,由于PE具有一定的抗UV的能量,从而改性PE/EVA层也就为其他层提供了保护。而将改性PMMA/EVA层作为最后层,由于PMMA的抗UV能力比较的强,从而也有效地增强了整体隔离条的抗UV作用。
优选为,所述改性PE/EVA层按质量份数计,由改性PE1~1.2份、EVA 100~110份、贝壳粉2~4份、氢氧化镁0.2~0.3份、钛白粉0.3~0.5份和碘化盐0.2~0.6份。
通过采用上述技术方案,由于贝壳粉中主要的成份为碳酸钙,其能够作为填充物加入到改性PE/EVA层中,从而有助于促进改性PE/EVA层的固化成型,提高了产品的成品率。
其次,碘化盐是一种良好的热稳定剂,其能够增强改性PE/EVA层的热稳定性,从而降低了因为太阳光照射时温度过高而导致隔离条损坏的概率。
而钛白粉是一种光稳定剂,其能够对紫外线起到一定的反射作用,从而有利于降低太阳光中的紫外线直接对改性PE/EVA层,进而也就有利于降低了隔离条老化的速率。
而氢氧化镁具有良好的阻燃作用,其能够降低隔离条在强太阳光的照射下,发生燃烧的概率。
优选为,所述贝壳粉经过含有碱性蛋白酶、木瓜蛋白酶和胰蛋白酶的酶液处理。
通过采用上述技术方案,由于贝壳粉经过上述酶液处理后的贝壳粉中会出现一种甲壳素,其不仅具有较强的粘性,能够提高改性PE/EVA层内部各物质之间的结合度。同时,甲壳素还是良好的抑菌剂,其能够有效地提高隔离条的抑菌性能,从而有利于降低隔离条被细菌或真菌所腐蚀的概率。
优选为,改性PE由质量百分数为65%~87%的PE和剩下的[2-羟基-4-(辛氧基)苯基]苯基酮组成。
通过采用上述技术方案,[2-羟基-4-(辛氧基)苯基]苯基酮能够与PE之间有良好的相溶性,且挥发率小,从而进一步提高了PE的抗UV的性能。
优选为,所述碘化盐为碘化亚铜和碘化锂的混合,且碘化亚铜和碘化锂的质量比为1∶1.2。
通过采用上述技术方案,碘化锂相较于其他碘化盐,不仅因为自身的物理性能而提高了改性PE/EVA层的稳定性能。同时,碘化锂中的锂离子还能够与改性PE/EVA层中的羰基之间存在配合作用,产生了类似网络的结构,阻碍了改性PE/EVA层的分子链及相应自由基的运动,因而使聚合物分子链在受热分解时比完全自由的分子链需克服更大的能垒,从而具有更高的热分解温度。
优选为,所述改性PMMA/EVA层按质量份数计,由改性PMMA 1.2~1.4份、EVA90~110份、卤化银0.4~0.6份、氧化铜0.01~0.02份和十二烷基苯磺酸钠0.1~0.3份组成。
通过采用上述技术方案,在阳光照射下,卤化银晶体中的银便会分离出来,处于游离状的银便在改性PMMA/EVA层内部形成小的聚集体。这些小的银聚集体呈犬牙交错的不规则块状,它们能够吸收阳光的紫外线,并使其转化成热能,从而也就降低了UV层对隔离条的老化作用。而等光变弱的时候,氧化铜又会催化卤素和银发生反应生产卤化银,进而隔离条整体的透光性能又会变好,这样既不影响光伏组件的采光,又能够有效地抵抗紫外线对隔离条所造成的老化。
十二烷基苯磺酸钠的加入一方面能够有利于促进各物质之间充分地进行溶合,另一方面其也有利于增强隔离条的抗静电性能,避免在加工过程中隔离条上沾染灰尘而降低使用效率。
优选为,所述卤化银为溴化银。
通过采用上述技术方案,溴化银中的溴元素能够进一步增强改性PMMA/EVA层的耐热性、化学腐蚀性、耐久性、耐候性和阻燃性,从而有利于进一步延长隔离条的使用寿命。
优选为,改性PMMA由质量分数为66%~83%的PMMA和剩下的2-(2′-羟基-3′-特丁基-5′-甲基苯基)-5-氯-苯并三唑组成。
通过采用上述技术方案,2-(2′-羟基-3′-特丁基-5′-甲基苯基)-5-氯-苯并三唑能够与PMMA上的酯基相结合,从而提高了PMMA的抗UV性能,这样也就进一步提高了隔离条的使用寿命。
一种用于光伏组件隔离条的生产方法:
步骤一,将PET层放卷至涂覆机上;
步骤二,对PET层进行电晕处理;
步骤三,对PET层两侧表面分别涂覆上EVA胶粘层,然后对EVA胶粘层进行UV紫外线固化,臭氧处理;
步骤四,对EVA胶粘层进行电晕处理
步骤五,通过涂覆机将改性PE/EVA层涂覆于PET层上方的EVA胶粘层上,将改性PMMA/EVA层涂覆于PET层下方的EVA胶粘层下;
步骤六,对改性PE/EVA层和改性PMMA/EVA层分别进行UV紫外线固化,臭氧处理,之后切割成成品的隔离条。
通过采用上述技术方案,该种隔离条整体生产比较的简便,并且在生产过程中经过多次UV固化和臭氧处理,有利于促使隔离条内部的性能趋于较为稳定的状态。
优选为,在PET层进入到涂布机前,通过防静电带对PET进行接触,去除静电。
通过采用上述技术方案,去除了PET层上的静电,这样能够避免生产过程中,灰尘沾覆到隔离条上,从而有利于提高隔离条的质量。
综上所述,本发明具有以下有益效果:
1、将改性PE/EVA层作为第一层,能够初步地对隔离条内部的其他层起到保护作用;
2、酶处理后的贝壳粉不仅能够有助于改性PE/EVA层的成型,同时也提高了隔离条的抑菌性能;
3、将碘化盐添加到改性PE/EVA层中,能够进一步提高改性PE/EVA层的稳定性;
4、在改性PMMA/EVA层中加入卤化银,这样银离子能够吸收紫外线,并将紫外线转化成银离子游离过程中的内能,从而也就降低了紫外线对改性PMMA/EVA层破坏。
附图说明
图1是隔离条的结构示意图。
图中,1、改性PE/EVA层;2、EVA胶粘层;3、PET层;4、改性PMMA/EVA层。
具体实施方式
以下结合附图1对本发明作进一步详细说明。
一种用于光伏组件隔离条的生产方法,
A.改性PE/EVA材料的生产:将PE和[2-羟基-4-(辛氧基)苯基]苯基酮混合,之后进行熔融,冷却,然后打碎成抗UV的改性PE母料;按规定质量将改性PE母料、EVA、贝壳粉、氢氧化镁、钛白粉和碘化盐进行熔融混合,得到流体改性PE/EVA材料。
其中,贝壳粉的制备方法:先配制pH为8.0的亚硫酸钠缓冲溶液,用少量曲拉通作为表面活性剂,分别使用碱性蛋白酶、木瓜蛋白酶和胰蛋白酶等酶的组合酶作催化,将贝壳浸泡于其中,控制恒温摇床温度为50℃,转速300r/min的条件下水解2小时。之后,将贝壳研磨成平均粒度为10μm的贝壳粉。
而碘化盐是由碘化亚铜和碘化锂混合,且碘化亚铜和碘化锂的质量比为1∶1.2。
B.改性PMMA/EVA材料的生产:将PMMA和2-(2′-羟基-3′-特丁基-5′-甲基苯基)-5-氯-苯并三唑混合,之后进行熔融,冷却,然后打碎成抗UV的改性PMMA母料;按规定质量将改性PMMA、EVA 90~110份、卤化银0.4~0.6份和十二烷基苯磺酸钠进行熔融混合,得到流体改性PMMA/EVA材料。
卤化银的选择可以根据实际情况来确定,此处卤化银优选为溴化银。
C.隔离条的涂覆生产:
步骤一,通过防静电带对150μm厚度的PET层3进行接触,去除静电,并将PET层3放卷至涂覆机上;
步骤二,利用高达10000V/m2的高频交流电压对PET层3进行电晕处理;
步骤三,对PET层3两侧表面分别涂覆上80μm厚度的EVA胶粘层2,然后对EVA胶粘层2进行UV紫外线固化,臭氧处理;
步骤四,对EVA胶粘层进行电晕处理;
步骤五,通过涂覆机将改性PE/EVA材料涂覆于PET层3上方的EVA胶粘层2上,形成800μm厚度的改性PE/EVA层1,将改性PMMA/EVA材料涂覆于PET层3下方的EVA胶粘层2下,形成100μm厚度的改性PMMA/EVA层4;
步骤六,对改性PE/EVA层1和改性PMMA/EVA层4分别进行UV紫外线固化,臭氧处理,之后切割成成品的隔离条。
根据上述一种用于光伏组件隔离条的生产方法设计了实施例一至实施例五,具体参数如下表所示:
将上述实施例一至实施例六的隔离条放入到200nm的紫外线和温度为100℃的环境中24小时,每个4小时观察隔离条的颜色变化得到,如下表所示结果;
时间/h | 实施例一 | 实施例二 | 实施例三 | 实施例四 | 实施例五 | 实施例六 |
4 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 |
8 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 |
12 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 |
16 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 |
20 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 | 无变化 |
24 | 微黄 | 无变化 | 无变化 | 微黄 | 无变化 | 无变化 |
从上表可以看出,本申请的隔离条具有较强的抗UV损坏和热稳定的性能,因而适合广泛在光伏领域进行使用。
将上述实施例一至实施例六的隔离条放置与带有培养液的培养皿中,然后在培养皿中加入10cfu的杂菌培养2小时,之后对菌落进行检测,得到如下表所示:
从上表中能够明显的看出,本隔离条还具有较强的抑菌作用,从而也就降低了隔离条在室外受到细菌或者真菌破坏的概率,从而也有利于延长隔离条的使用寿命。
本具体实施例仅仅是对本发明的解释,其并不是对本发明的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本发明的权利要求范围内都受到专利法的保护。
Claims (10)
1.一种用于光伏组件隔离条,其特征在于:自上而下,第一层为改性PE/EVA层(1),第二层为EVA胶粘层(2),第三层为PET层(3),第四层为EVA胶粘层(2)和第五层为改性PMMA/EVA层(4)。
2.根据权利要求1所述的一种用于光伏组件隔离条,其特征在于:所述改性PE/EVA层(1)按质量份数计,由改性PE 1~1.2份、EVA 100~110份、贝壳粉2~4份、氢氧化镁0.2~0.3份、钛白粉0.3~0.5份和碘化盐0.2~0.6份。
3.根据权利要求2所述的一种用于光伏组件隔离条,其特征在于:所述贝壳粉经过含有碱性蛋白酶、木瓜蛋白酶和胰蛋白酶的酶液处理。
4.根据权利要求2所述的一种用于光伏组件隔离条,其特征在于:改性PE由质量百分数为65%~87%的PE和剩下的[2-羟基-4-(辛氧基)苯基]苯基酮组成。
5.根据权利要求2所述的一种用于光伏组件隔离条,其特征在于:所述碘化盐为碘化亚铜和碘化锂的混合,且碘化亚铜和碘化锂的质量比为1∶1.2。
6.根据权利要求1所述的一种用于光伏组件隔离条,其特征在于:所述改性PMMA/EVA层(3)按质量份数计,由改性PMMA 1.2~1.4份、EVA 90~110份、卤化银0.4~0.6份、氧化铜0.01~0.02份和十二烷基苯磺酸钠0.1~0.3份组成。
7.根据权利要求6所述的一种用于光伏组件隔离条,其特征在于:所述卤化银为溴化银。
8.根据权利要求6所述的一种用于光伏组件隔离条,其特征在于:改性PMMA由质量分数为66%~83%的PMMA和剩下的2-(2′-羟基-3′-特丁基-5′-甲基苯基)-5-氯-苯并三唑组成。
9.如权利要求1至8中任意一项权利要求所述的一种用于光伏组件隔离条的生产方法:
步骤一,将PET层(3)放卷至涂覆机上;
步骤二,对PET层(3)进行电晕处理;
步骤三,对PET层(3)两侧表面分别涂覆上EVA胶粘层(2),然后对EVA胶粘层(2)进行UV紫外线固化,臭氧处理;
步骤四,对EVA胶粘层(2)进行电晕处理
步骤五,通过涂覆机将改性PE/EVA层(1)涂覆于PET层(3)上方的EVA胶粘层(2)上,将改性PMMA/EVA层(4)涂覆于PET层(3)下方的EVA胶粘层(2)下;
步骤六,对改性PE/EVA层(1)和改性PMMA/EVA层(4)分别进行UV紫外线固化,臭氧处理,之后切割成成品的隔离条。
10.根据权利要求9所述的一种用于光伏组件隔离条的生产方法,其特征在于:在PET层(3)进入到涂布机前,通过防静电带对PET进行接触,去除静电。
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CN109294339A (zh) * | 2018-09-18 | 2019-02-01 | 宁海县震洋文教用品有限公司 | 一种透明易洗固体水彩及其制备方法 |
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