CN111844986A - 一种无氟多层共挤太阳能背板膜及其制备方法 - Google Patents
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Abstract
本发明涉及一种无氟多层共挤太阳能背板膜，所述的太阳能背板膜为五层高分子材料的共挤膜；该五层高分子材料的共挤膜为共聚烯烃耐候层、阻隔层、聚烯烃支撑层、聚烯烃功能层和粘结功能层共五层共挤而成，厚度400‑500μm；具体厚度按照比例：共聚烯烃耐候层：阻隔层：聚烯烃支撑层：聚烯烃功能层：粘结功能层5＝25：1：50：14：110。本发明的太阳能背板膜具备优异的抗冲击性、长期耐热性、耐热变色性、抗静电性能和尺寸稳定性，太阳能背板不分层，不开裂，质量好，实现支撑层的耐环境应力开裂和支撑性，且加工成本低，特别是直接节约下游生产的加工工序和成本，即节约光伏组件的加工工序和成本，对整个光伏组件来说也是产效更高、成本更低、产量更大。
Description
技术领域
本发明涉及太阳能背板技术领域，具体涉及一种无氟多层共挤太阳能背板膜及其制备方法。
背景技术
太阳能背板膜也称为太阳能背板、太阳能电池背板、太阳能电池背板膜、光伏背板、光伏背板膜。因太阳能电池装置于室外，经常会出现由于高温、紫外线、风雨等原因导致的产品老化，发电效率低下等问题。太阳能背板膜可以作为一层保护膜将太阳能电池的内侧包裹起来，大大延长太阳能电池的使用寿命，其广泛应用于太阳能电池光伏组件，位于太阳能电池板的背面，对电池片起保护和支撑作用，具有可靠的绝缘性、阻水性、耐老化性。参照图1、2，现有的太阳能背板膜包括依次设置的耐候氟膜层、支撑层PET、粘结层涂层(含氟涂料)制备而成，生产光伏组件再与EVA加热到140℃复合，其抗冲击性、抗静电性能、耐热变色性等结构以及化学属性有待提高、且生产成本高，特别是生产出的太阳能背板膜至下游的光伏组件生产，还需与EVA加热复合，加工工序多且成本更高。
发明内容
本发明目的是提供一种无氟多层共挤太阳能背板膜及其制备方法，本发明的太阳能背板膜具备优异的抗冲击性、长期耐热性、耐热变色性、抗静电性能和尺寸稳定性，太阳能背板不分层，不开裂，质量好，实现支撑层的耐环境应力开裂和支撑性，且加工成本低，特别是直接节约下游生产的加工工序和成本，即节约光伏组件的加工工序和成本，对整个光伏组件来说也是产效更高、成本更低、产量更大。
为了实现以上目的，本发明采用的技术方案为：一种无氟多层共挤太阳能背板膜，所述的太阳能背板膜为五层高分子材料的共挤膜；该五层高分子材料的共挤膜为共聚烯烃耐候层、阻隔层、聚烯烃支撑层、聚烯烃功能层和粘结功能层共五层共挤而成，厚度400-500μm；具体厚度按照比例：共聚烯烃耐候层：阻隔层：聚烯烃支撑层：聚烯烃功能层：粘结功能层5＝25：1：50：14：110。
进一步的，所述的太阳能背板膜厚度400μm。
再进一步的，所述的共聚烯烃耐候层厚度50μm，原料为96％改性高等规共聚抗冲聚丙烯(HIPP)，填充1.5％钛白粉、0.5％ZnO和2.0％滑石粉。
再进一步的，所述的阻隔层厚度2μm，为高透明乙烯-乙烯醇共聚物(EVOH)，与所述的共聚烯烃耐候层共同实现水汽的阻隔性。
进一步的，所述的聚烯烃支撑层厚度100μm，原料为PP含量占比75％，共混线性低密度聚乙烯(共混LLDPE)含量占比20％，填充滑石粉占比5％。
再进一步的，所述的填充滑石粉的粉粒径小于或等于12μm。
进一步的，所述的聚烯烃功能层厚度28μm，原料为98.5％线性低密度聚乙烯(LLDPE)，填充抗老化母料1.5％。
进一步的，所述的粘结功能层厚度220μm，原料为EVA，其熔融温度低于95℃。
一种无氟多层共挤太阳能背板膜的制备方法，包括以下步骤：
1)配方料斗分别将各层配方提供给五台挤出机，经分层模头实现五层组分共挤成膜；
2)模头流出的熔体迅速贴附冷辊铸片；
3)经冷却、自然风除水、修边后收卷，从而得到无氟多层共挤太阳能背板膜。
再进一步的，挤出机的长径比为25：1——33：1。
本发明的技术效果在于：本发明的太阳能背板膜具备优异的抗冲击性、长期耐热性、耐热变色性、抗静电性能和尺寸稳定性，太阳能背板不分层，不开裂，质量好，实现支撑层的耐环境应力开裂和支撑性，且加工成本低，特别是直接节约下游生产的加工工序和成本，即节约光伏组件的加工工序和成本，对整个光伏组件来说也是产效更高、成本更低、产量更大。
附图说明
图1为现有的太阳能背板膜结构图；
图2为现有的太阳能背板膜应用在光伏组件上的结构图；
图3为本发明的太阳能背板膜的结构图；
图4为本发明的太阳能背板膜应用在光伏组件上的结构图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
参照图3、4，本发明的一种无氟多层共挤太阳能背板膜，所述的太阳能背板膜为五层高分子材料的共挤膜。本发明太阳能背板膜无需覆氟膜和涂覆含氟涂料即可达到太阳能背板膜的要求，且自带胶膜，与电池片可直接热压合。加工成本低。
该五层高分子材料的共挤膜为共聚烯烃耐候层1、阻隔层2、聚烯烃支撑层3、聚烯烃功能层4和粘结功能层5共五层共挤而成，厚度400μm。
其中聚烯烃功能层4为过渡层，可有效粘结聚烯烃支撑层3和粘结功能层5的EVA，长期使用不分层，质量好。并且直接将EVA共挤在太阳能背板膜形成粘结功能层5，直接节约下游生产的加工工序和成本，即节约光伏组件的加工工序和成本，对整个光伏组件来说也是产效更高、成本更低、产量更大。
进一步的，所述的共聚烯烃耐候层1厚度50μm，原料为96％改性高等规共聚抗冲聚丙烯(HIPP)，填充1.5％钛白粉、0.5％ZnO和2.0％滑石粉。
实验温度为(85±2)℃，相对湿度为(85±5)％的恒温恒湿试验箱中进行处理5000h，黄变指数ΔYi≤1.5。150℃，30分钟环境下测试热收缩TD、MD≤0.5％，且共聚聚丙烯本身具有耐酸碱腐蚀的特性。
这样，得到的产品具备优异的抗冲击性、长期耐热性、耐紫外性、耐酸碱腐蚀性和尺寸稳定性。
再进一步的，所述的阻隔层2厚度2μm，为高透明乙烯-乙烯醇共聚物(EVOH)，与所述的共聚烯烃耐候层1共同实现水汽的阻隔性。
即通过EVOH阻水阻氧。
进一步的，所述的聚烯烃支撑层3厚度100μm，原料为PP含量占比75％，共混线性低密度聚乙烯(共混LLDPE)含量占比20％，填充滑石粉占比5％。
PCT测试(测试条件：121℃；90％RH；2大气压)快速老化，参照图4，采用太阳能模组或者光伏组件(即图中电池片20)用封装EVA30压制在毛玻璃板(即图中玻璃40)上(太阳能背板膜/EVA/玻璃)，其中压制条件由组件封装工艺根据EVA种类选定，放入PCT试验箱96h，太阳能背板不分层，不开裂。
实现支撑层(依托聚烯烃支撑层3)的耐环境应力开裂和支撑性。
再进一步的，所述的填充滑石粉的粉粒径小于或等于12μm。
进一步的，所述的聚烯烃功能层4厚度28μm，原料为98.5％线性低密度聚乙烯(LLDPE)，填充抗老化母料1.5％。
进一步的，所述的粘结功能层5厚度220μm，原料为EVA，其熔融温度低于95℃。
现有的太阳能背板膜的一面(内侧面)后期要与EVA加热到140℃复合，另一面(外侧面)裸露在空气中。本发明的无氟多层共挤太阳能背板膜形成的共挤膜自带EVA粘结层(粘结功能层5)和耐候层(共聚烯烃耐候层1)，裸露空气中，共聚烯烃耐候层1具有耐酸碱腐蚀，耐风沙刮伤和耐高低温等性能，起到保护光伏组件的作用。聚烯烃支撑层3主要是实现整个太阳能背板的挺度和耐环境应力开裂，粘结功能层5可直接与电池片20热压合。具体参照图4。
本发明的无氟多层共挤太阳能背板膜总厚度400-500μm，具体厚度按照共聚烯烃耐候层1：阻隔层2：聚烯烃支撑层3：聚烯烃功能层4：粘结功能层5＝25：1：50：14：110进行。
基于上述组分方案，一种无氟多层共挤太阳能背板膜的制备方法，其特征在于，包括以下步骤：
1)配方料斗分别将各层配方提供给五台挤出机，经分层模头实现五层组分共挤成膜；
2)模头流出的熔体迅速贴附冷辊铸片；
3)经冷却、自然风除水、修边后收卷，从而得到无氟多层共挤太阳能背板膜。
进一步的，挤出机的长径比为25：1——33：1。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (10)
1.一种无氟多层共挤太阳能背板膜，其特征在于，所述的太阳能背板膜为五层高分子材料的共挤膜；该五层高分子材料的共挤膜为共聚烯烃耐候层(1)、阻隔层(2)、聚烯烃支撑层(3)、聚烯烃功能层(4)和粘结功能层(5)共五层共挤而成，厚度400-500μm；具体厚度按照比例：共聚烯烃耐候层(1)：阻隔层(2)：聚烯烃支撑层(3)：聚烯烃功能层(4)：粘结功能层(5)＝25：1：50：14：110。
2.根据权利要求1所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的太阳能背板膜厚度400μm。
3.根据权利要求2所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的共聚烯烃耐候层(1)厚度50μm，原料为96％改性高等规共聚抗冲聚丙烯(HIPP)，填充1.5％钛白粉、0.5％ZnO和2.0％滑石粉。
4.根据权利要求3所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的阻隔层(2)厚度2μm，为高透明乙烯-乙烯醇共聚物(EVOH)，与所述的共聚烯烃耐候层(1)共同实现水汽的阻隔性。
5.根据权利要求2所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的聚烯烃支撑层(3)厚度100μm，原料为PP含量占比75％，共混线性低密度聚乙烯(共混LLDPE)含量占比20％，填充滑石粉占比5％。
6.根据权利要求5所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的填充滑石粉的粉粒径小于或等于12μm。
7.根据权利要求2所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的聚烯烃功能层(4)厚度28μm，原料为98.5％线性低密度聚乙烯(LLDPE)，填充抗老化母料1.5％。
8.根据权利要求2所述的一种无氟多层共挤太阳能背板膜，其特征在于：所述的粘结功能层(5)厚度220μm，原料为EVA，其熔融温度低于95℃。
9.一种无氟多层共挤太阳能背板膜的制备方法，其特征在于，包括以下步骤：
1)配方料斗分别将各层配方提供给五台挤出机，经分层模头实现五层组分共挤成膜；
2)模头流出的熔体迅速贴附冷辊铸片；
3)经冷却、自然风除水、修边后收卷，从而得到无氟多层共挤太阳能背板膜。
10.根据权利要求9所述的一种无氟多层共挤太阳能背板膜的制备方法，其特征在于，包括以下步骤：挤出机的长径比为25：1——33：1。
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| CN114702915B (zh) * | 2021-12-31 | 2024-01-12 | 浙江中聚材料有限公司 | 一种多层共挤出薄膜材料及其制备方法 |
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