CN110077067B - 双层共挤抗极化型eva复合胶膜及其制备方法 - Google Patents
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Abstract
本发明涉及太阳能光伏组件用封装胶膜技术领域，特别是一种双层共挤抗极化型EVA复合胶膜，包括从上而下依次设置的共聚物树脂抗极化层和EVA树脂层，所述共聚物树脂抗极化层和EVA树脂层采用双层共挤而成。采用上述结构和方法后，本发明不仅能够解决光伏组件层压过程中的气泡、未融和并片问题，还能够解决组件的PID问题，从而提高组件封装良品率，降低光伏电站的PID风险，且制备方法过程简单实用，具有很高的工业生产价值。
Description
技术领域
本发明涉及太阳能光伏组件用封装胶膜技术领域，特别是一种双层共挤抗极化型EVA复合胶膜及其制备方法。
背景技术
传统的太阳能光伏组件用封装胶膜主要是乙烯-醋酸乙烯酯共聚物（EVA)胶膜，且胶膜中的VA（醋酸乙烯脂）含量需要大于25%。由于EVA是极性树脂，与极性助剂相容性较好，在组件层压时不容易产生气泡、未融和并片问题。但是太能光伏组件在发电过程中，通过外边框会产生负电压，从而导致玻璃中的钠离子和钾离子穿过胶膜层到达电池片表面，在电池片表面集聚形成正电场，进而导致电池片内部产生负电荷集聚形成负电场来抗衡，减少了电池片中的载流子，从而降低电池片的发电效率，产生PID现象。
发明内容
本发明需要解决的技术问题是提供一种能有效解决光伏组件PID问题的双层共挤抗极化型EVA复合胶膜及其制备方法。
为解决上述技术问题，本发明的双层共挤抗极化型EVA复合胶膜，包括从上而下依次设置的共聚物树脂抗极化层和EVA树脂层，所述共聚物树脂抗极化层和EVA树脂层采用双层共挤而成。
优选的，所述的共聚物树脂抗极化层中共聚物树脂采用EAA、EMA、PTW中的一种或几种。
优选的，所述的EAA树脂丙烯酸酯含量为5%-30%，熔点为60-85℃，熔融指数为5-20g/10min；所述的EMA树脂丙烯酸酯含量为8%-35%，熔点为55-80℃，熔融指数为3-18g/10min；所述的PTW树脂丙烯酸酯含量为10%-30%，熔点为58-80℃，熔融指数为6-25g/10min。
优选的，所述的EVA树脂层中EVA树脂熔体流动速率为10—30g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为45—90℃，VA含量20-30%。
优选的，所述的共聚物树脂抗极化层厚度为0.1-0.4mm。
优选的，所述的EVA树脂层厚度为0.2-0.6mm。
本发明还公开了一种双层共挤抗极化型EVA复合胶膜的制备方法，先将卧式混料机加热到40-50℃；然后将树脂料粒计量好加入到卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度5-10r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到10-25r/min，先正转搅拌10-20min，再反转搅拌10-20min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃；聚合物树脂抗极化层和EVA树脂层分别采用两个卧式混料机分开混料，都采用上述混料工艺同时混料；
待助剂吸收到料粒中后，再采用单螺杆挤出工艺制备双层共挤抗极化型EVA复合胶膜。
优选的，所述单螺杆挤出工艺为混合好的两种物料分别送入两台单螺杆挤出机，挤出温度都为80-100℃，两台挤出机挤出的物料进入同一个双层共挤模头，然后经压花、冷却、牵引、收卷等制备工序。
采用上述方法和结构后，本发明具有以下优点：
1.与电池面接触的EVA层与极性助剂相容性较好，能够解决组件层压时的气泡、未融和并片问题；
2.抗极化层中的共聚物树脂含有的乙烯链段与EVA相容性较好，可以形成较强的表面粘接；聚物树脂中含有的丙烯酸酯链段对钠离子和钾离子具有较强的螯合能力，可以减少钠离子和钾离子穿过胶膜层到达电池片表面的数量，并且丙烯酸酯具有较强的被极化性能，降低组件通过外边框产生负电压值，从而提高组件的抗PID性能；
3.在卧式混料机的混合工艺下，能够将液体助剂完全吸收到树脂料粒当中，从而使后续下料到挤出机过程中料粒之间不会粘结到一起造成堵料，且能够促进挤出熔融状态下液体助剂更均匀、更快的在树脂流体当中分散，制备的复合膜批次稳定性跟好。
4.通过双层共挤的加工方法，设备简单，生产效率高，生产成本低。
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为本发明双层共挤抗极化型EVA复合胶膜整体结构的侧视图。
图中：1为共聚物树脂抗极化层，2为EVA树脂层。
具体实施方式
如图1所示，本发明的双层共挤抗极化型EVA复合胶膜，包括从上而下依次设置的共聚物树脂抗极化层1和EVA树脂层2，所述共聚物树脂抗极化层1和EVA树脂层2采用双层共挤而成。
实施例1
（1）将计量好的EAA树脂（丙烯酸酯含量为25%，熔点为69℃，熔融指数为8.5g/10min）加入到第一台卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度5r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到12r/min，先正转搅拌20min，再反转搅拌20min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃。同时将计量好的EVA树脂（熔体流动速率为25g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为56℃，VA含量28%）加入到第一个卧式混料机中，采用与第一台相同的卧式混料机混料工艺进行混料。（2）将两台卧式混料机混合好的物料分别送入两台单螺杆挤出机，挤出温度都为80-100℃，两台挤出机挤出的物料进入同一个双层共挤模头，控制好共聚物树脂抗极化层挤出厚度为0.4mm、EVA树脂层挤出厚度为0.4mm，然后经压花、冷却、牵引、收卷等制备工序制备出抗极化型EVA复合胶膜。
表1列出了抗极化型EVA复合胶膜的性能测试结果
实施例2
（1）将计量好的EMA树脂（丙烯酸酯含量为30%，熔点为61℃，熔融指数为4g/10min）加入到第一台卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度8r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到18r/min，先正转搅拌15min，再反转搅拌15min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃。同时将计量好的EVA树脂（熔体流动速率为20g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为54℃，VA含量25%）加入到第一个卧式混料机中，采用与第一台相同的卧式混料机混料工艺进行混料。（2）将两台卧式混料机混合好的物料分别送入两台单螺杆挤出机，挤出温度都为80-100℃，两台挤出机挤出的物料进入同一个双层共挤模头，控制好共聚物树脂抗极化层挤出厚度为0.3mm、EVA树脂层挤出厚度为0.5mm，然后经压花、冷却、牵引、收卷等制备工序制备出抗极化型EVA复合胶膜。
表1列出了抗极化型EVA复合胶膜的性能测试结果
实施例3
（1）将计量好的PTW树脂（丙烯酸酯含量为25.5%，熔点为73℃，熔融指数为12g/10min）加入到第一台卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度5r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到15r/min，先正转搅拌15min，再反转搅拌15min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃。同时将计量好的EVA树脂（熔体流动速率为20g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为54℃，VA含量25%）加入到第一个卧式混料机中，采用与第一台相同的卧式混料机混料工艺进行混料。（2）将两台卧式混料机混合好的物料分别送入两台单螺杆挤出机，挤出温度都为80-100℃，两台挤出机挤出的物料进入同一个双层共挤模头，控制好共聚物树脂抗极化层挤出厚度为0.2mm、EVA树脂层挤出厚度为0.6mm，然后经压花、冷却、牵引、收卷等制备工序制备出抗极化型EVA复合胶膜。
表1列出了抗极化型EVA复合胶膜的性能测试结果
对比例1
（1）将计量好的EVA树脂（熔体流动速率为25g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为56℃，VA含量28%）加入到卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度5r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到12r/min，先正转搅拌20min，再反转搅拌20min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃。（2）将卧式混料机混合好的物料送入单螺杆挤出机，挤出温度都为80-100℃，挤出机挤出的物料进入单层模头，控制好EVA树脂层挤出厚度为0.8mm，然后经压花、冷却、牵引、收卷等制备工序制备出普通EVA胶膜。
表1列出了普通EVA胶膜的性能测试结果
对比例2
（1）将计量好的EVA树脂（熔体流动速率为20g/10min，透光率＞86%，体积电阻率≥1.0×1014，熔融温度为54℃，VA含量25%）加入到卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度8r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到18r/min，先正转搅拌15min，再反转搅拌15min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃。（2）将卧式混料机混合好的物料送入单螺杆挤出机，挤出温度都为80-100℃，挤出机挤出的物料进入单层模头，控制好EVA树脂层挤出厚度为0.8mm，然后经压花、冷却、牵引、收卷等制备工序制备出普通EVA胶膜。
表1列出了普通EVA胶膜的性能测试结果
表1 实施例和对比例样品的性能测试数据表
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 (2)
1.一种双层共挤抗极化型EVA复合胶膜，其特征在于：包括从上而下依次设置的共聚物树脂抗极化层和EVA树脂层，所述共聚物树脂抗极化层和EVA树脂层采用双层共挤而成；
先将卧式混料机加热到40-50℃；然后将树脂料粒计量好加入到卧式混料机中；再将计量好、混合均匀的引发剂、助交联剂、偶联剂、紫外稳定剂、紫外吸收剂和抗氧剂的混合液体通过液体喷料装置均匀喷洒到树脂粒子当中，边喷洒边搅拌，搅拌速度5-10r/min，计量喷洒10min，喷洒过程中保持卧式混料机恒温40-50℃；喷洒结束后，将搅拌速度提高到10-25r/min，先正转搅拌10- 20min，再反转搅拌10-20min，使液体混合助剂完全被树脂粒子吸收，搅拌过程中保持卧式混料机恒温40-50℃；共聚物树脂抗极化层和EVA树脂层分别采用两个卧式混料机分开混料；待助剂吸收到料粒中后，再采用单螺杆挤出工艺制备双层共挤抗极化型EVA复合胶膜；
共聚物树脂抗极化层中共聚物树脂采用EMA或PTW，所述的EMA树脂中丙烯酸酯含量为8%-35%，熔点为55-80℃，熔融指数为3-18g/10min；所述的PTW树脂中丙烯酸酯含量为10%-30%，熔点为58-80℃，熔融指数为6-25g/10min；
所述的EVA树脂层中EVA树脂熔体流动速率为10—30g/10min，透光率＞86%，体积电阻率≥1 .0×1014Ω·cm，熔融温度为45—90℃，VA含量20-30%；
所述的共聚物树脂抗极化层厚度为0 .1-0 .4mm；
所述的EVA树脂层厚度为0 .2-0 .6mm。
2.根据权利要求1所述的一种双层共挤抗极化型EVA复合胶膜，其特征在于：所述单螺杆挤出工艺为混合好的两种物料分别送入两台单螺杆挤出机，挤出温度都为80-100℃，两台挤出机挤出的物料进入同一个双层共挤模头，然后经压花、冷却、牵引、收卷制备工序。
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