CN110003801A - 一种三层复合高可靠高效增益eva光伏胶膜及其制备方法 - Google Patents
一种三层复合高可靠高效增益eva光伏胶膜及其制备方法 Download PDFInfo
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- CN110003801A CN110003801A CN201910185409.8A CN201910185409A CN110003801A CN 110003801 A CN110003801 A CN 110003801A CN 201910185409 A CN201910185409 A CN 201910185409A CN 110003801 A CN110003801 A CN 110003801A
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- 150000001875 compounds Chemical class 0.000 title claims abstract description 45
- 239000003292 glue Substances 0.000 title claims abstract description 36
- 238000002360 preparation method Methods 0.000 title claims description 7
- 238000004132 cross linking Methods 0.000 claims abstract description 16
- 239000002313 adhesive film Substances 0.000 claims abstract description 12
- 239000002131 composite material Substances 0.000 claims abstract description 12
- 230000005855 radiation Effects 0.000 claims abstract description 8
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 108
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 108
- 239000010410 layer Substances 0.000 claims description 101
- 239000003963 antioxidant agent Substances 0.000 claims description 36
- 230000003078 antioxidant effect Effects 0.000 claims description 36
- 235000006708 antioxidants Nutrition 0.000 claims description 36
- 239000003431 cross linking reagent Substances 0.000 claims description 23
- -1 β-(3,5- di-tert-butyl-hydroxy phenyl) Propionic acid octadecanol ester Chemical class 0.000 claims description 22
- 239000003795 chemical substances by application Substances 0.000 claims description 17
- 229920005989 resin Polymers 0.000 claims description 14
- 239000011347 resin Substances 0.000 claims description 14
- 150000002148 esters Chemical class 0.000 claims description 13
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 12
- ZREORSWVGSDDPP-UHFFFAOYSA-N (4-nonylphenyl) dihydrogen phosphite Chemical class CCCCCCCCCC1=CC=C(OP(O)O)C=C1 ZREORSWVGSDDPP-UHFFFAOYSA-N 0.000 claims description 10
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 10
- 229910000077 silane Inorganic materials 0.000 claims description 10
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 10
- 229920002554 vinyl polymer Polymers 0.000 claims description 10
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical group O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 8
- 239000004611 light stabiliser Substances 0.000 claims description 8
- ISIJQEHRDSCQIU-UHFFFAOYSA-N tert-butyl 2,7-diazaspiro[4.5]decane-7-carboxylate Chemical compound C1N(C(=O)OC(C)(C)C)CCCC11CNCC1 ISIJQEHRDSCQIU-UHFFFAOYSA-N 0.000 claims description 8
- BJELTSYBAHKXRW-UHFFFAOYSA-N 2,4,6-triallyloxy-1,3,5-triazine Chemical compound C=CCOC1=NC(OCC=C)=NC(OCC=C)=N1 BJELTSYBAHKXRW-UHFFFAOYSA-N 0.000 claims description 6
- 238000007766 curtain coating Methods 0.000 claims description 6
- 230000005496 eutectics Effects 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 150000001451 organic peroxides Chemical class 0.000 claims description 6
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 5
- 238000000576 coating method Methods 0.000 claims description 5
- 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 claims description 4
- XMNIXWIUMCBBBL-UHFFFAOYSA-N 2-(2-phenylpropan-2-ylperoxy)propan-2-ylbenzene Chemical compound C=1C=CC=CC=1C(C)(C)OOC(C)(C)C1=CC=CC=C1 XMNIXWIUMCBBBL-UHFFFAOYSA-N 0.000 claims description 4
- OKKRPWIIYQTPQF-UHFFFAOYSA-N Trimethylolpropane trimethacrylate Chemical compound CC(=C)C(=O)OCC(CC)(COC(=O)C(C)=C)COC(=O)C(C)=C OKKRPWIIYQTPQF-UHFFFAOYSA-N 0.000 claims description 4
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 4
- 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 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- OBNCKNCVKJNDBV-UHFFFAOYSA-N butanoic acid ethyl ester Natural products CCCC(=O)OCC OBNCKNCVKJNDBV-UHFFFAOYSA-N 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 4
- LSXWFXONGKSEMY-UHFFFAOYSA-N di-tert-butyl peroxide Chemical compound CC(C)(C)OOC(C)(C)C LSXWFXONGKSEMY-UHFFFAOYSA-N 0.000 claims description 4
- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 claims description 4
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 claims description 4
- 238000001125 extrusion Methods 0.000 claims description 4
- 239000000945 filler Substances 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 4
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 claims description 4
- 239000004408 titanium dioxide Substances 0.000 claims description 4
- NKLOIQIDDWPNFE-UHFFFAOYSA-N [SiH4].C(C)(C)(C)OOC(C)(C)C Chemical compound [SiH4].C(C)(C)(C)OOC(C)(C)C NKLOIQIDDWPNFE-UHFFFAOYSA-N 0.000 claims description 3
- 239000011247 coating layer Substances 0.000 claims description 3
- 238000010894 electron beam technology Methods 0.000 claims description 3
- 239000000155 melt Substances 0.000 claims description 3
- 239000005416 organic matter Substances 0.000 claims description 3
- ZXDDPOHVAMWLBH-UHFFFAOYSA-N 2,4-Dihydroxybenzophenone Chemical group OC1=CC(O)=CC=C1C(=O)C1=CC=CC=C1 ZXDDPOHVAMWLBH-UHFFFAOYSA-N 0.000 claims description 2
- JTXMVXSTHSMVQF-UHFFFAOYSA-N 2-acetyloxyethyl acetate Chemical compound CC(=O)OCCOC(C)=O JTXMVXSTHSMVQF-UHFFFAOYSA-N 0.000 claims description 2
- 229920001076 Cutan Polymers 0.000 claims description 2
- FMRHJJZUHUTGKE-UHFFFAOYSA-N Ethylhexyl salicylate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1O FMRHJJZUHUTGKE-UHFFFAOYSA-N 0.000 claims description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 claims description 2
- 239000012965 benzophenone Substances 0.000 claims description 2
- 239000006229 carbon black Substances 0.000 claims description 2
- 238000005253 cladding Methods 0.000 claims description 2
- 229920006026 co-polymeric resin Polymers 0.000 claims description 2
- HDERJYVLTPVNRI-UHFFFAOYSA-N ethene;ethenyl acetate Chemical compound C=C.CC(=O)OC=C HDERJYVLTPVNRI-UHFFFAOYSA-N 0.000 claims description 2
- 229920001038 ethylene copolymer Polymers 0.000 claims description 2
- DXGLGDHPHMLXJC-UHFFFAOYSA-N oxybenzone Chemical group OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1 DXGLGDHPHMLXJC-UHFFFAOYSA-N 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 230000002035 prolonged effect Effects 0.000 claims description 2
- 238000005096 rolling process Methods 0.000 claims description 2
- 238000007493 shaping process Methods 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims 3
- SPTHWAJJMLCAQF-UHFFFAOYSA-N 1,2-di(propan-2-yl)benzene;hydrogen peroxide Chemical compound OO.CC(C)C1=CC=CC=C1C(C)C SPTHWAJJMLCAQF-UHFFFAOYSA-N 0.000 claims 2
- XFCMNSHQOZQILR-UHFFFAOYSA-N 2-[2-(2-methylprop-2-enoyloxy)ethoxy]ethyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCCOCCOC(=O)C(C)=C XFCMNSHQOZQILR-UHFFFAOYSA-N 0.000 claims 2
- XKXIQBVKMABYQJ-UHFFFAOYSA-M tert-butyl carbonate Chemical compound CC(C)(C)OC([O-])=O XKXIQBVKMABYQJ-UHFFFAOYSA-M 0.000 claims 2
- 125000003903 2-propenyl group Chemical group [H]C([*])([H])C([H])=C([H])[H] 0.000 claims 1
- DBOSBRHMHBENLP-UHFFFAOYSA-N 4-tert-Butylphenyl Salicylate Chemical compound C1=CC(C(C)(C)C)=CC=C1OC(=O)C1=CC=CC=C1O DBOSBRHMHBENLP-UHFFFAOYSA-N 0.000 claims 1
- NHEAGJSSRBGIBS-UHFFFAOYSA-N [Si].C(C)(C)(C)OOC(C)(C)C Chemical compound [Si].C(C)(C)(C)OOC(C)(C)C NHEAGJSSRBGIBS-UHFFFAOYSA-N 0.000 claims 1
- 239000002253 acid Substances 0.000 claims 1
- 150000001335 aliphatic alkanes Chemical class 0.000 claims 1
- RZJRJXONCZWCBN-UHFFFAOYSA-N alpha-octadecene Natural products CCCCCCCCCCCCCCCCCC RZJRJXONCZWCBN-UHFFFAOYSA-N 0.000 claims 1
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 claims 1
- 238000007334 copolymerization reaction Methods 0.000 claims 1
- 150000002118 epoxides Chemical class 0.000 claims 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Natural products OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 claims 1
- 150000002576 ketones Chemical class 0.000 claims 1
- 229940038384 octadecane Drugs 0.000 claims 1
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 claims 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 claims 1
- 235000010215 titanium dioxide Nutrition 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 8
- 230000000694 effects Effects 0.000 abstract description 5
- 238000010438 heat treatment Methods 0.000 abstract description 2
- 238000003475 lamination Methods 0.000 abstract description 2
- OKIRBHVFJGXOIS-UHFFFAOYSA-N 1,2-di(propan-2-yl)benzene Chemical compound CC(C)C1=CC=CC=C1C(C)C OKIRBHVFJGXOIS-UHFFFAOYSA-N 0.000 description 4
- KOMNUTZXSVSERR-UHFFFAOYSA-N 1,3,5-tris(prop-2-enyl)-1,3,5-triazinane-2,4,6-trione Chemical compound C=CCN1C(=O)N(CC=C)C(=O)N(CC=C)C1=O KOMNUTZXSVSERR-UHFFFAOYSA-N 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- DKTKWMAFBNGURD-UHFFFAOYSA-N tert-butyl 2-ethylhexyl carbonate Chemical compound CCCCC(CC)COC(=O)OC(C)(C)C DKTKWMAFBNGURD-UHFFFAOYSA-N 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000003490 calendering Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 238000002310 reflectometry Methods 0.000 description 3
- OSNIIMCBVLBNGS-UHFFFAOYSA-N 1-(1,3-benzodioxol-5-yl)-2-(dimethylamino)propan-1-one Chemical compound CN(C)C(C)C(=O)C1=CC=C2OCOC2=C1 OSNIIMCBVLBNGS-UHFFFAOYSA-N 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- QYJVHXFJGNNXGU-UHFFFAOYSA-N 3,3-bis(tert-butylperoxy)butanoic acid Chemical compound CC(C)(C)OOC(C)(CC(O)=O)OOC(C)(C)C QYJVHXFJGNNXGU-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 2
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 2
- 239000007983 Tris buffer Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000005538 encapsulation Methods 0.000 description 2
- 125000004494 ethyl ester group Chemical group 0.000 description 2
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000002978 peroxides Chemical class 0.000 description 2
- 229940113165 trimethylolpropane Drugs 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
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- C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
- C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
- C09J123/04—Homopolymers or copolymers of ethene
- C09J123/08—Copolymers of ethene
- C09J123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
- C09J123/0853—Vinylacetate
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
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- H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
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Abstract
本发明涉及EVA光伏胶膜技术领域,特别是一种三层复合高可靠高效增益EVA光伏胶膜,由上层透明EVA层,中间白色反光EVA层及下层透明EVA层构成;所述上层透明EVA层为透明EVA流延复合层,厚度在25~200μm;中间白色反光EVA层表面设置有金字塔型的反光结构,厚度在250~550μm;下层透明EVA层为透明EVA流延复合共挤层,厚度在50~225μm。采用上述方法后,本发明的高可靠性高增益白色EVA胶膜具有与电池片粘结强度高,组件可靠性好的特点。同时比常规白色EVA胶膜具有更高的放光率及更好的反射效果,结构正面经过辐照交联后其表面结构不会受到层压过程中的加热而融化,保证了高反光结构的完整性,提高了电池片间隙之间的反射光线的漫反射效果,使得组件功率得到大大提升。
Description
技术领域
本发明涉及EVA光伏胶膜技术领域,特别是一种三层复合高可靠高效增益EVA光伏胶膜及其制备方法。
背景技术
近十几年来,由于技术进步和国家光伏政策的影响,我国光伏产业的发展非常迅猛,自2008年以来,产量和产值超过德国、日本等光伏强国位居世界第一。但是,目前太阳能电池光电转化效应难以提高,一直维持在19%~21%之间,而且由电池片封装成组件后其还存在一个封装损耗,因此如何提高光伏电池的光电转换效率成为世界光伏产业关注的焦点和各国政府新能源产业布局的重要参考。而组件之所以存在封装损耗,这些损失的来源是多方面的,其中包括电池片间的间隔以及电池片与组件边缘的空白处。
太阳能光伏组件基本结构由上到下由5层组成:上层高透型光伏玻璃﹑上层EVA胶膜﹑电池片﹑下层EVA胶膜﹑光伏背板或下层光伏玻璃。由于这种结构,太阳光从玻璃入射,经过上层EVA胶膜,到达电池片实现光电转换,太阳光在电池片间的间隔以及电池片与组件边缘的空白处的光线都会漏掉,如果最下面是光伏玻璃,那么太阳光会直接射出100%都损失掉,如果是光伏背板,由于背板反射率不高,只有70-80%的光线被反射到电池片表面继续发电,这样也有20-30%的太阳光被损失掉。目前常规的白色EVA胶膜仍然存在增益效果有限、反射率低等影响很难在进一步提升组件的发电效率,同时常规的白色EVA胶膜为了解决白膜的褶皱和溢白等外观问题,一般都采用电子辐射预处理技术,但是目前电子辐射技术应用在光伏领域的时间较短,电子辐射发生器工作并不稳定,容易造成辐射的不均匀性,且辐照预交联技术的白膜对组件的可靠性还存在一定的影响,造成剥离强度偏低的情况。因此,开发一款高可靠性高增益的白色EVA胶膜就成为太阳能产业界研究的热点。
发明内容
本发明需要解决的技术问题是提供一种高可靠白色高效增益EVA光伏胶膜。
为解决上述技术问题,本发明的一种三层复合高可靠高效增益EVA光伏胶膜的制备方法,由上层透明EVA层,中间白色反光EVA层及下层透明EVA层构成;所述上层透明EVA层为透明EVA流延复合层,厚度在25~200μm;中间白色反光EVA层表面设置有金字塔型的反光结构,厚度在250~550μm;下层透明EVA层为透明EVA流延复合共挤层,厚度在50~225μm。
优选的,所述上、下层透明EVA层按照质量百分比计包括以下组分:乙烯-醋酸乙烯共聚物树脂含量为 90%~99%,抗氧剂含量为 0.03%~2%,光稳定剂含量为0.01~0.65%,交联剂含量为0.20%~2.1%,硅烷偶联剂含量为0.1%~2%。
优选的,所述乙烯-醋酸乙烯共聚物树脂中醋酸乙烯的摩尔含量为20%~50%,所述乙烯-醋酸乙烯共聚物树脂的熔体流动速率为0.5g/10min~25g/10min。
优选的,所述抗氧剂包括主抗氧剂和辅抗氧剂,其中,所述主抗氧基为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和/或亚磷酸三(2,4-二叔丁基苯基)酯。
优选的,所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
优选的,所述光稳定剂为2,4-二羟基二苯甲酮、2-羟基-4-甲氧基二苯甲酮、2-羟基-4-正辛氧基二苯甲酮中的一种。
优选的,所述光稳定剂为2-羟基-4-甲氧基二苯甲酮。
优选的,所述交联剂包括交联固化剂和助交联剂,所述交联固化剂包括有机过氧化物和/或偶氮化合物,所述有机过氧化物包括为过氧化异丙苯、二叔丁基过氧化物、过氧化氢二异丙苯、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)丁酸乙酯中的一种或几种;所述助交联剂包括三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯、三羟甲基丙烷三甲基丙烯酸酯、二甲基丙烯酸二乙二醇酯中的一种或多种混合。
优选的,所述硅烷偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、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。
优选的,所述中间白色反光EVA层按照质量百分比计包括以下组分:低熔指乙烯-醋酸乙烯共聚物树脂含量为76%~85%,抗氧剂含量为 0.03%~3%,交联剂含量为0.20%~2.1%,硅烷偶联剂含量为0.06%~4.1%,白色填料含量为5.0%~20.0%。
优选的,所述白色填料为钛白粉,白炭黑,硫酸钡的白色颗粒,表面经过有机物和无机物包覆处理,加工成25-75%浓度的EVA白色母粒后使用。
优选的,所述低熔指乙烯-醋酸乙烯共聚物树脂中醋酸乙烯的摩尔含量为30%~55%,所述低熔指乙烯-醋酸乙烯共聚物树脂的熔体流动速率为0.5g/10min~15g/10min。
优选的,所述抗氧剂包括主抗氧剂和辅抗氧剂,其中,所述主抗氧剂为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和/或亚磷酸三(2,4-二叔丁基苯基)酯。
优选的,所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
优选的,所述交联剂包括交联固化剂和助交联剂,所述交联固化剂包括有机过氧化物和/或偶氮化合物,所述有机过氧化物包括为过氧化异丙苯、二叔丁基过氧化物、过氧化氢二异丙苯、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)丁酸乙酯中的一种或几种;所述助交联剂包括三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯、三羟甲基丙烷三甲基丙烯酸酯、二甲基丙烯酸二乙二醇酯中的一种或多种混合。
优选的,所述硅烷偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、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。
优选的,所述EVA光伏胶膜的总厚度为350~800μm。
本发明还公开了一种三层复合高可靠高效增益EVA光伏胶膜的制备方法,包括以下步骤,
先将上、下层透明EVA层按比例将熔指乙烯-醋酸乙烯共聚物,抗氧剂及交联剂和硅烷偶联剂加入高速混合机充分混合5~10min;同时将中间白色反光EVA层按比例将熔指乙烯-醋酸乙烯共聚物,白色母粒、抗氧剂及交联剂和硅烷偶联剂加入另一台高混机充分混合5~10min;
然后将混合好的透明EVA树脂和白色EVA树脂分别放入两个挤出料斗,进行双层螺杆共挤流延或压延;
将流延或者压延出的白色与透明共挤的胶膜将白色胶层面经过带有金字塔型的冷却钢棍进行急速压花并冷却;
将冷却成型的白色复合胶膜具有金字塔结构的面经过高能电子束的正面辐照交联定型,得到复合反光层和透明胶层;
将得到的具有反光结构且经过电子辐照的复合胶层经过流延涂敷设备涂敷一层透明EVA胶层在反光结构层表面,然后经压花-定型-切边-收卷-包装得到三层复合高可靠高增益白色EVA胶膜。
采用上述方法后,本发明的高可靠性高增益白色EVA胶膜具有与电池片粘结强度高,组件可靠性好的特点。同时比常规白色EVA胶膜具有更高的放光率及更好的反射效果,结构正面经过辐照交联后其表面结构不会受到层压过程中的加热而融化,保证了高反光结构的完整性,提高了电池片间隙之间的反射光线的漫反射效果,使得组件功率得到大大提升。
附图说明
下面结合附图和具体实施方式对本发明作进一步详细的说明。
图1为本发明一种三层复合高可靠高效增益EVA光伏胶膜的结构示意图。
图2为本发明中间白色反光EVA层的反光结构示意图。
图中:1为上层透明EVA层,2为中间白色反光EVA层,3为下层透明EVA层,4为反光结构。
具体实施方式
如图1所示,本发明的一种三层复合高可靠高效增益EVA光伏胶膜的制备方法,由上层透明EVA层1,中间白色反光EVA层2及下层透明EVA层3构成;所述上层透明EVA层1为透明EVA流延复合层,厚度在25~200μm;中间白色反光EVA层表面设置有金字塔型的反光结构,厚度在250~550μm;下层透明EVA层为透明EVA流延复合共挤层,厚度在50~225μm。本发明EVA光伏胶膜的总厚度为350~800μm。
第一步中间白色反光EVA层复合膜生产工艺及配方设计:
主料:乙烯-醋酸乙烯共聚物(EVA),VA含量为28%。
钛白粉:表面经过有机物包覆处理,加工成30-70%浓度的EVA白色母粒后使用。
抗氧剂:主抗氧基为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
交联剂:交联固化剂为过氧化2-乙基己基碳酸叔丁酯和3,3-二(叔丁基过氧)丁酸乙酯的复配物;助交联剂为三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯和三羟甲基丙烷三甲基丙烯酸酯的复配物。
硅烷偶联剂:乙烯基三(β-甲氧基乙氧基)硅烷。
白色胶层配方按照EVA:钛白粉:抗氧剂:交联剂:硅烷偶联剂=100-X:X:0.1:2:0.6,X=5.0-20.0,将上述材料按表1的比例充分混合均匀,分别加入到两个挤出机料斗,进行熔融共挤出,挤出机、模头各区域的温度设定为80~100℃,经挤出流延或者压延,金字塔结构辊压花,高能电子束辐照交联,得到具有反光结构的白色EVA复合胶层。
第二步上、下层透明EVA层流延涂敷及配方设计:
主料:乙烯-醋酸乙烯共聚物(EVA),VA含量为33%。
抗氧剂:主抗氧基为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
光稳定剂:2-羟基-4-正辛氧基二苯甲酮。
交联剂:交联固化剂为过氧化2-乙基己基碳酸叔丁酯和3,3-二(叔丁基过氧)丁酸乙酯的复配物;助交联剂为三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯和三羟甲基丙烷三甲基丙烯酸酯的复配物。
硅烷偶联剂:乙烯基三(β-甲氧基乙氧基)硅烷。
配方按照EVA:抗氧剂:光稳定剂:交联剂:硅烷偶联剂=97: 0.3:0.4:2:0.3将上述材料按比例充分混合均匀,分别加入到两个挤出机料斗,进行熔融共挤出,挤出机、模头各区域的温度设定为70~90℃,经过流延涂敷设备涂敷一层透明EVA胶层在反光结构复合膜层表面,一层在白膜层背面,然后经压花-定型-切边-收卷-包装得到三层复合高可靠高增益白色EVA胶膜;
本专利的生产工艺流程为:混料-流延或者压延共挤-中间白色反光EVA层结构定型-中间白色反光EVA层辐照交联-与上、下层透明EVA层进行涂敷-压花-冷却-裁切-收卷-包装,最后包装入库。然后进行胶膜反射率、封装组件外观测试和封装组件功率测试。
表1—各实施实例白配方及测试数据
由以上实施实例可以看出,该高可靠高增益反光白色EVA胶膜可同时采用流延和压延共挤法并经过涂敷进行生产,同时采用反光结构辐照预交联的技术保证了反光结构的完整性,有效提高了该白膜反射光线后的漫反射,使得组件功率得到了大大的提升。同时该复合白膜与玻璃的粘结强度高,组件在经过UV60KWh和DH1000h后的老化测试后剥离强度均高于60N/cm,可靠性好。
虽然以上描述了本发明的具体实施方式,但是本领域熟练技术人员应当理解,这些仅是举例说明,可以对本实施方式作出多种变更或修改,而不背离本发明的原理和实质,本发明的保护范围仅由所附权利要求书限定。
Claims (18)
1.一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:由上层透明EVA层,中间白色反光EVA层及下层透明EVA层构成;所述上层透明EVA层为透明EVA流延复合层,厚度在25~200μm;中间白色反光EVA层表面设置有金字塔型的反光结构,厚度在250~550μm;下层透明EVA层为透明EVA流延复合共挤层,厚度在50~225μm。
2.按照权利要求1所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于,所述上、下层透明EVA层按照质量百分比计包括以下组分:乙烯-醋酸乙烯共聚物树脂含量为90%~99%,抗氧剂含量为 0.03%~2%,光稳定剂含量为0.01~0.65%,交联剂含量为0.20%~2.1%,硅烷偶联剂含量为0.1%~2%。
3.按照权利要求2所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述乙烯-醋酸乙烯共聚物树脂中醋酸乙烯的摩尔含量为20%~50%,所述乙烯-醋酸乙烯共聚物树脂的熔体流动速率为0.5g/10min~25g/10min。
4.按照权利要求2所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述抗氧剂包括主抗氧剂和辅抗氧剂,其中,所述主抗氧基为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和/或亚磷酸三(2,4-二叔丁基苯基)酯。
5.按照权利要求4所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
6.按照权利要求2所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述光稳定剂为2,4-二羟基二苯甲酮、2-羟基-4-甲氧基二苯甲酮、2-羟基-4-正辛氧基二苯甲酮中的一种。
7.按照权利要求6所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述光稳定剂为2-羟基-4-甲氧基二苯甲酮,水杨酸对叔丁基苯酯,2-羟基-4-异辛氧基二苯甲酮,2-羟基-4-正辛氧基二苯甲酮,2-羟基-4-十八烷氧基二苯甲酮中的一种或几种。
8.按照权利要求2所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述交联剂包括交联固化剂和助交联剂,所述交联固化剂包括有机过氧化物和/或偶氮化合物,所述有机过氧化物包括为过氧化异丙苯、二叔丁基过氧化物、过氧化氢二异丙苯、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)丁酸乙酯中的一种或几种;所述助交联剂包括三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯、三羟甲基丙烷三甲基丙烯酸酯、二甲基丙烯酸二乙二醇酯中的一种或多种混合。
9.按照权利要求2所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述硅烷偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、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。
10.按照权利要求1所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于,所述中间白色反光EVA层按照质量百分比计包括以下组分:低熔指乙烯-醋酸乙烯共聚物树脂含量为76%~85%,抗氧剂含量为 0.03%~3%,交联剂含量为0.20%~2.1%,硅烷偶联剂含量为0.06%~4.1%,白色填料含量为5.0%~20.0%。
11.按照权利要求10所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述白色填料为钛白粉,白炭黑,硫酸钡的白色颗粒,表面经过有机物和无机物包覆处理,加工成25-75%浓度的EVA白色母粒后使用。
12.按照权利要求10所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述低熔指乙烯-醋酸乙烯共聚物树脂中醋酸乙烯的摩尔含量为30%~55%,所述低熔指乙烯-醋酸乙烯共聚物树脂的熔体流动速率为0.5g/10min~15g/10min。
13.按照权利要求10所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述抗氧剂包括主抗氧剂和辅抗氧剂,其中,所述主抗氧剂为β-(3,5-二叔丁基-4-羟基苯基)丙酸十八碳醇酯;所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和/或亚磷酸三(2,4-二叔丁基苯基)酯。
14.按照权利要求13所述一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述辅抗氧剂为三(4-壬基酚)亚磷酸酯和亚磷酸三(2,4-二叔丁基苯基)酯的复配物。
15.按照权利要求10所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述交联剂包括交联固化剂和助交联剂,所述交联固化剂包括有机过氧化物和/或偶氮化合物,所述有机过氧化物包括为过氧化异丙苯、二叔丁基过氧化物、过氧化氢二异丙苯、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)丁酸乙酯中的一种或几种;所述助交联剂包括三烯丙基异氰脲酸酯、三聚氰酸三烯丙酯、三羟甲基丙烷三甲基丙烯酸酯、二甲基丙烯酸二乙二醇酯中的一种或多种混合。
16.按照权利要求10所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述硅烷偶联剂为乙烯基三乙氧基硅烷、乙烯基三甲氧基硅烷、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。
17.按照权利要求1-16中任一项所述的一种三层复合高可靠高效增益EVA光伏胶膜,其特征在于:所述EVA光伏胶膜的总厚度为350~800μm。
18.一种三层复合高可靠高效增益EVA光伏胶膜的制备方法,其特征在于,包括以下步骤,
先将上、下层透明EVA层按比例将熔指乙烯-醋酸乙烯共聚物,抗氧剂及交联剂和硅烷偶联剂加入高速混合机充分混合5~10min;同时将中间白色反光EVA层按比例将熔指乙烯-醋酸乙烯共聚物,白色母粒、抗氧剂及交联剂和硅烷偶联剂加入另一台高混机充分混合5~10min;
然后将混合好的透明EVA树脂和白色EVA树脂分别放入两个挤出料斗,进行双层螺杆共挤流延或压延;
将流延或者压延出的白色与透明共挤的胶膜将白色胶层面经过带有金字塔型的冷却钢棍进行急速压花并冷却;
将冷却成型的白色复合胶膜具有金字塔结构的面经过高能电子束的正面辐照交联定型,得到复合反光层和透明胶层;
将得到的具有反光结构且经过电子辐照的复合胶层经过流延涂敷设备涂敷一层透明EVA胶层在反光结构层表面,然后经压花-定型-切边-收卷-包装得到三层复合高可靠高增益白色EVA胶膜。
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