CN110978720A - 一种耐高温碳纤维复合材料载板的制备方法 - Google Patents

一种耐高温碳纤维复合材料载板的制备方法 Download PDF

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CN110978720A
CN110978720A CN201911210195.1A CN201911210195A CN110978720A CN 110978720 A CN110978720 A CN 110978720A CN 201911210195 A CN201911210195 A CN 201911210195A CN 110978720 A CN110978720 A CN 110978720A
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carbon fiber
temperature
fiber composite
composite material
carrier plate
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李三平
杨正
刘鹏
杨翠翠
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Wuxi Zhishang New Material Technology Co ltd
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Abstract

本发明公开了一种耐高温碳纤维复合材料载板的制备方法，其步骤包括：碳纤维干布→将聚酰亚胺预浸料涂覆到碳纤维干布表面→烘干→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板的厚度叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→机械加工→耐高温碳纤维复合材料载板。通过本申请公开的制备方法获得的耐高温碳纤维复合材料载板，能够耐受400℃‑600℃的工作温度，遇到明火表现出阻燃、低烟、低毒排放等特性，能大大提升产品应用的安全性。

Description

一种耐高温碳纤维复合材料载板的制备方法
技术领域
本发明属于碳纤维复合材料技术领域，具体涉及一种光伏电池生产用耐高温碳纤维复合材料载板的制备方法。
背景技术
碳纤维(carbon fiber，简称CF)，是一种含碳量在95％以上的高强度、高模量纤维的新型纤维材料。它是由片状石墨微晶等有机纤维沿纤维轴向方向堆砌而成，经碳化及石墨化处理而得到的微晶石墨材料。碳纤维“外柔内刚”，质量比金属铝轻，但强度却高于钢铁，并且具有耐腐蚀、高模量的特性，在国防军工和民用方面都是重要材料。它不仅具有碳材料的固有本征特性，又兼备纺织纤维的柔软可加工性，是新一代增强纤维。
碳纤维具有许多优良性能，碳纤维的轴向强度和模量高，密度低、比性能高，无蠕变，非氧化环境下耐超高温，耐疲劳性好，比热及导电性介于非金属和金属之间，热膨胀系数小且具有各向异性，耐腐蚀性好，X射线透过性好。良好的导电导热性能、电磁屏蔽性好等，因此，碳纤维的应用领域非常广泛。
太阳能电池板背面钝化技术是近来光伏产业中的热门话题，通过背面钝化技术能有效地提高晶体硅太阳电池的开路电压和短路电流，从而促进太阳电池的转换率。但是与传统的晶硅电池技术不同的是，背面钝化技术增加了背面钝化膜制备和背面钝化膜开孔两道工艺流程，在提高太阳电池转换效率的同时，无疑是增加了工艺的复杂程度，大幅度地提升了晶硅电池的制作成本，这也成为背面钝化技术在光伏产业中深度应用的主要障碍。为了解决太阳能电池转换效率与成本之间的矛盾，行业内正在尝试推广和使用新的技术方案，力求解决由技术上的制约导致的成本高的技术问题，消除该工艺对降低生产成本的消极影响。
耐高温碳纤维复合材料载板可用于太阳能电池板背面钝化工艺生产；目前市场中应用的耐高温碳纤维复合材料载板，其制作成本高，导致晶硅电池的制作成本大幅度地提升，影响了改技术在行业中的推广应用。
发明内容
本发明所要解决的技术问题是：提供一种光伏电池生产用耐高温碳纤维复合材料载板的制备方法。
为解决上述技术问题，本发明采用的技术方案为：一种耐高温碳纤维复合材料载板的制备方法，其步骤包括：碳纤维干布→将聚酰亚胺(PI)预浸料涂覆到碳纤维基材表面→烘干→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板的厚度(一般为3～6mm)叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→根据形状尺寸机械加工→耐高温碳纤维复合材料载板。
所述的聚酰亚胺(PI)预浸料：其由聚酰亚胺(PI)与溶剂组成，其中，聚酰亚胺(PI)质量百分含量为68％～70％，所述的溶剂为乙醇或丙酮。
所述的碳纤维预浸湿布，其中聚酰亚胺(PI)固含量占比为40±3Wt.％。所述的碳纤维预浸湿布一般在7天内进行加热、加压固化定型，放置时间超过7天后，碳纤维预浸湿布性能会下降，不易成型。
所述的加热、加压固化定型，其过程为：将碳纤维预浸湿布置于固化定型设备中，分别在80±2℃加热1～1.5小时、160±5℃加热1～1.5小时、280±5℃加热1～1.5小时、360±5℃加热1～1.5小时，且在加热过程中保持压力为6～8MPa条件下压制，360℃～200℃自然冷却(聚酰亚胺收缩比与碳纤维不同，此温度段冷却过快，易出现大面积扭曲)，＜200℃自然冷却或利用水加速冷却，成型，得耐高温碳纤维复合材料板材。
所述的碳纤维干布，其厚度为0.2±0.005mm。
所述的烘干，该过程中，烘干温度为100～120℃，烘干时间为120～150秒。
本发明有益效果：经过耐高温碳纤维复合材料载板样品实验以及批量化应用证明，使用耐高温碳纤维复合材料载板对此有的积极效应——这种适用于PERC(PassivatedEmitter and Rear Cell)电池镀膜和背面钝化等太阳能电池片镀膜工艺的碳纤维载板不仅可以在高达400～600℃的高温下保持材料的稳定性，而且对减少镀膜过程中的边缘效应和提高产能方面表现出明显的优势。
通过本申请公开的制备方法获得的耐高温碳纤维复合材料载板，完全可以替代日本进口产品(且成本低，国外同类产品售价3万/平米左右，本公司产品实现1.2-1.5万/平米)，最高能够耐受800℃的温度，遇到明火则表现出阻燃、低烟、低毒排放等特性，能大大提升产品应用的安全性。
具体实施方式
实施例1
所述的耐高温碳纤维复合材料载板的制备方法，其步骤包括：0.2±0.005mm的碳纤维干布→根据尺寸裁剪→将聚酰亚胺(PI)预浸料涂覆到碳纤维基材表面→温度为110～115℃，烘干120～150秒→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板厚度(5mm)叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→根据形状尺寸机械加工→耐高温碳纤维复合材料载板。
所述的聚酰亚胺(PI)预浸料：其由聚酰亚胺(PI)与乙醇组成，其中，聚酰亚胺(PI)质量百分含量为68％。
所述的碳纤维预浸湿布，其中聚酰亚胺(PI)固含量占比为40±3Wt.％。
所述的加热、加压固化定型，其过程为：将碳纤维预浸湿布置于固化定型设备中，分别在80℃/1小时、160℃/1小时、280℃/1小时、360℃/1小时、压力为6～7MPa条件下压制，360℃～200℃自然冷却(聚酰亚胺收缩比与碳纤维不同，此温度段冷却过快，易出现大面积扭曲)，＜200℃可以利用水冷加速冷却，成型，得耐高温碳纤维复合材料板材。
所述的耐高温碳纤维复合材料载板的性能：
抗压强度：≥3000MPa；
工作温度达：≤800℃。
实施例2
所述的耐高温碳纤维复合材料载板的制备方法，其步骤包括：0.2±0.005mm的碳纤维干布→根据尺寸裁剪→将聚酰亚胺(PI)预浸料涂覆到碳纤维基材表面→温度为110～120℃，烘干120～150秒→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板厚度(5mm)叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→根据形状尺寸机械加工→耐高温碳纤维复合材料载板。
所述的聚酰亚胺(PI)预浸料：其由聚酰亚胺(PI)与丙酮组成，其中，聚酰亚胺(PI)质量百分含量为70％。
所述的碳纤维预浸湿布，其中聚酰亚胺(PI)固含量占比为40±3Wt.％。
所述的加热、加压固化定型，其过程为：将碳纤维预浸湿布置于固化定型设备中，分别在80℃/1小时、165℃/1小时、285℃/1小时、365℃/1.5小时、压力为7～8MPa条件下压制，360℃～200℃自然冷却(聚酰亚胺收缩比与碳纤维不同，此温度段冷却过快，易出现大面积扭曲)，＜200℃可以利用水冷加速冷却，成型，得耐高温碳纤维复合材料板材。
所述的耐高温碳纤维复合材料载板的性能：
抗压强度：≥3000MPa；
工作温度达：≤800℃。
实施例3
所述的耐高温碳纤维复合材料载板的制备方法，其步骤包括：0.2±0.005mm的碳纤维干布→根据尺寸裁剪→将聚酰亚胺(PI)预浸料涂覆到碳纤维基材表面→温度为115～120℃，烘干120～150秒→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板厚度(5mm)叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→根据形状尺寸机械加工→耐高温碳纤维复合材料载板。
所述的聚酰亚胺(PI)预浸料：其由聚酰亚胺(PI)与乙醇组成，其中，聚酰亚胺(PI)质量百分含量为69％。
所述的碳纤维预浸湿布，其中聚酰亚胺(PI)固含量占比为40±3Wt.％。
所述的加热、加压固化定型，其过程为：将碳纤维预浸湿布置于固化定型设备中，分别在80℃/1小时、165℃/1小时、280℃/1.5小时、365℃/1小时、压力为7～8MPa条件下压制，360℃～200℃自然冷却(聚酰亚胺收缩比与碳纤维不同，此温度段冷却过快，易出现大面积扭曲)，＜200℃可以利用水冷加速冷却，成型，得耐高温碳纤维复合材料板材。
所述的耐高温碳纤维复合材料载板的性能：
抗压强度：≥3000MPa；
工作温度达：≤800℃。
实施例1-3所得耐高温碳纤维复合材料载板，能够耐受≤800℃的温度，遇到明火则表现出阻燃、低烟、低毒排放等特性。
使用所述的耐高温型碳纤维复合材料用于电池片背面钝化处理，在整个工艺流程中，所述的耐高温碳纤维复合材料板材的耐温性和材料强度等方面效果都更加理想。特别是在设备高模块速度运行时，不仅可以在电池片周边避免常见的物理损害，还能将电池片周边原有的面接触改为线接触，极大地减少镀膜过程中的边缘效应，可以将产能提高至3000-3500pcs/h。

Claims (6)

1.一种耐高温碳纤维复合材料载板的制备方法，其步骤包括：碳纤维干布→将聚酰亚胺预浸料涂覆到碳纤维干布表面→烘干→收卷→得到碳纤维预浸湿布→根据耐高温碳纤维复合材料载板的厚度叠加碳纤维预浸湿布→加热、加压固化定型→得耐高温碳纤维复合材料板材→机械加工→耐高温碳纤维复合材料载板。
2.根据权利要求1所述的一种耐高温碳纤维复合材料载板的制备方法，其特征在于：所述的加热、加压固化定型，其过程为：将叠加好的碳纤维预浸湿布置于固化定型设备中，分别在80±2℃加热1～1.5h、160±5℃加热1～1.5h、280±5℃加热1～1.5h、360±5℃加热1～1.5h，且在加热过程中保持压力为6～8MPa条件下压制，360℃～200℃自然冷却，＜200℃自然冷却或利用水冷，成型，得耐高温碳纤维复合材料板材。
3.根据权利要求1或2所述的一种耐高温碳纤维复合材料载板的制备方法，其特征在于：所述的聚酰亚胺预浸料：其由聚酰亚胺与溶剂组成，其中，聚酰亚胺质量百分含量为68％～70％，所述的溶剂为乙醇或丙酮。
4.根据权利要求1或2所述的一种耐高温碳纤维复合材料载板的制备方法，其特征在于：所述的碳纤维预浸湿布，其中聚酰亚胺固含量占比为40±3Wt.％。
5.根据权利要求1或2所述的一种耐高温碳纤维复合材料载板的制备方法，其特征在于：所述的碳纤维干布，其厚度为0.2±0.005mm。
6.根据权利要求1或2所述的一种耐高温碳纤维复合材料载板的制备方法，其特征在于：所述的烘干，该过程中，烘干温度为100～120℃，烘干时间为120～150秒。
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