CN112225992A - 一种光伏用双层共挤出po薄膜及其制备方法 - Google Patents
一种光伏用双层共挤出po薄膜及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种光伏用双层共挤出PO薄膜及其制备方法,PO薄膜由内层、外层两层结构组成,内层是改性的均聚聚丙烯材料,通过均聚聚丙烯的高耐温性,提供更高的有效绝缘厚度(DTI)保留率,充分保证了1500V光伏产品的使用安全性,降低了局部电压击穿风险,再辅之低密度聚乙烯、共聚聚丙烯和相容剂,不仅通过胶水能够与PET具有良好的粘结性能,同时还降低了双层结构分层的风险;外层是改性共聚聚丙烯材料,通过添加低密度聚乙烯、线性低密度聚乙烯和相容剂,从而提高其与光伏组件中的EVA胶膜的粘接性能,同时提供优异的户外耐老化性能,可以有效、长久的保护户外基材。
Description
技术领域
本发明涉及光伏用封装保护膜技术领域,具体涉及光伏用双层共挤出PO薄膜及其制备方法。
背景技术
长久以来,高额的光伏发电成本始终是制约光伏产业迅速发展的障碍之一。如何有效降低光伏系统的成本、提高发电效率仍将是未来光伏产业发展的核心课题。为了满足降低成本的需求,近年来1500V相关光伏产品正逐步替代1000V相关光伏产品。1500V系统电压会降低电气的安全性和可靠性,同时增大PID等风险。因此制作1500V光伏组件主要考虑背板局放、电连接器和电绝缘等影响组件可靠性和安全性的因素,其难点主要在于光伏发电设备的主角—光伏组件,而光伏组件的关键绝缘结构是光伏背板。因此,开发1500V安全光伏背板便成了问题的关键。
光伏背板位于光伏电池板的背面,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,常见的背板类型有TPT、KPK、TPE、KPE、AAA、FPF等(其中:T指杜邦的聚氟乙烯薄膜(PVF),K指聚偏氟乙烯薄膜(PVDF),E指乙烯-醋酸乙烯膜或者聚乙烯膜,A指改性聚酰胺膜,F指氟碳涂料,P指聚对苯二甲酸乙二醇酯薄膜)。其中,在一些非特别关键的组件上,市场多采用TPE结构。然而,由于1500V光伏产品的推广,导致此类背板在使用安全性能上存在较大隐患,其主要原因为EVA或PE的耐温性差,组件生产过程中的层压工艺会导致背板的有效绝缘厚度(DTI)降低。目前,市场中已有的PP薄膜也无法同时满足上述性能要求。
发明内容
本发明的目的是为了解决现有技术中的问题,提供一种有效绝缘厚度(DTI)保留率高、阻隔紫外性能优良,且易于与EVA胶膜粘接的,对环境无污染的光伏用双层共挤出PO薄膜及其制备方法。
为了达到上述目的,本发明的技术方案是:
一种光伏用双层共挤出PO薄膜,具有共挤出形成的内层和外层两层结构,所述内层为改性均聚聚丙烯层,所述外层为改性共聚聚丙烯层。
优选的,所述内层的厚度为20~40微米,所述外层的厚度为20~40微米,所述PO薄膜总厚度50~70微米。
优选的,所述内层由以下质量份的原料制成,
优选的,所述外层由以下质量份的原料制成,
优选的,所述均聚聚丙烯和共聚聚丙烯的熔融指数均为5~30g/10min、2.16kg、230℃;所述低密度聚乙烯和线性低密度聚乙烯的熔融指数均为1~10g/10min、2.16kg、190℃。
优选的,所述抗氧剂为受阻酚类抗氧剂、受阻胺类抗氧剂、亚磷酸酯类抗氧剂、硫酯类抗氧剂中的至少一种。
优选的,所述紫外吸收剂为水杨酸酯类紫外吸收剂、苯酮类紫外吸收剂、取代丙烯腈类紫外吸收剂、三嗪类紫外吸收剂与受阻胺类紫外吸收剂中的至少一种。
优选的,所述相容剂为POE、EVA、EAA、EEA、EMAA、EMA、EBA、EPDM中的至少一种。
优选的,所述填充粉体为硫酸钡、滑石粉、钛白粉、氧化锌、碳酸钙中的至少一种。
一种光伏用双层共挤出PO薄膜的制备方法,包括以下步骤,
S1,按照内层和外层原料配比,将内层和外层原料分别经过高速混合机混合,混合时间为5~30分钟,混合转速300~1200rpm;混合后的内层和外层原料分别投入到双螺杆挤出机,在170~210℃下进行熔融、分散与挤出造粒,分别得到内层、外层的改性料颗粒;
S2,将内层、外层的改性料分别投入双层共挤流涎机的两台单螺杆机挤出机内,在170~230℃进行熔化输送,并汇流至流涎模头,模头温度为170~235℃,经模头挤出后拉伸、冷却定型,切边收卷,从而得到所述PO薄膜。
本发明的有益效果是:本发明的一种光伏用双层共挤出PO薄膜与现有产品相比,其优点在于本发明的光伏用双层共挤出PO薄膜具有两层结构,内层是改性的均聚聚丙烯材料,通过均聚聚丙烯的高耐温性,提供更高的有效绝缘厚度(DTI)保留率,充分保证了1500V光伏产品的使用安全性,降低了局部电压击穿风险,再辅之低密度聚乙烯、共聚聚丙烯和相容剂,不仅通过胶水能够与PET具有良好的粘结性能,同时还降低了双层结构分层的风险;外层是改性共聚聚丙烯材料,通过添加低密度聚乙烯、线性低密度聚乙烯和相容剂,从而提高其与光伏组件中的EVA胶膜(常见为白色胶膜和透明胶膜两种,其中白色胶膜更难粘接)的粘接性能。同时,填充粉体、抗氧剂及紫外吸收剂的添加,为双层共挤出PO薄膜提供了优异的耐热黄变和阻隔紫外性能。
附图说明
图1为本发明光伏用双层共挤出PO薄膜的一种结构示意图。
具体实施方式
为了使本技术领域的人员更好地理解本发明方案,下面结合附图和实施方式对本发明创造作进一步的详细说明。
如图1所示的一种光伏用双层共挤出PO薄膜,具有共挤出形成的内层1和外层2两层结构,所述内层1为改性均聚聚丙烯层,所述外层2为改性共聚聚丙烯层。优选的,所述内层1的厚度为20~40微米,所述外层2的厚度为20~40微米,所述PO薄膜总厚度50~70微米。
其中,所述内层1由以下质量份的原料制成,
所述外层2由以下质量份的原料制成,
优选的,所述均聚聚丙烯和共聚聚丙烯的熔融指数均为5~30g/10min、2.16kg、230℃;所述低密度聚乙烯和线性低密度聚乙烯的熔融指数均为1~10g/10min、2.16kg、190℃。所述抗氧剂为受阻酚类抗氧剂、受阻胺类抗氧剂、亚磷酸酯类抗氧剂、硫酯类抗氧剂中的至少一种。所述紫外吸收剂为水杨酸酯类紫外吸收剂、苯酮类紫外吸收剂、取代丙烯腈类紫外吸收剂、三嗪类紫外吸收剂与受阻胺类紫外吸收剂中的至少一种。所述相容剂为POE、EVA、EAA、EEA、EMAA、EMA、EBA、EPDM中的至少一种。所述填充粉体为硫酸钡、滑石粉、钛白粉、氧化锌、碳酸钙中的至少一种。
下面例举四种不同的改性料配方的实施例1-4,参见表1。各实施例中采用的原料如下:
内层配方:
均聚聚丙烯,牌号为K1814(供应商为:燕山石化,熔融指数为13.5g/10min,2.16kg,230℃);
共聚聚丙烯,牌号为K7726(供应商为:燕山石化,熔融指数为26g/10min,2.16kg,230℃);
低密度聚乙烯,牌号为2426K(供应商为:扬子巴斯夫,熔融指数为4g/10min,2.16kg,190℃);
相容剂,POE(牌号为8200,供应商为:陶氏化学)。
填充粉体,滑石粉与氧化锌按照2:1比例混合。
抗氧剂,受阻酚类抗氧剂(商品名为:抗氧剂-1098和抗氧剂-168,两者按照1:1比例混合,供应商为:德国BASF公司)。
紫外吸收剂,苯并三唑类(商品名为:UV-234,供应商为:德国BASF公司)。
外层配方:
共聚聚丙烯,牌号为K7726(供应商为:燕山石化,熔融指数为26g/10min,2.16kg,230℃);
线性低密度聚乙烯,牌号为1002YB(供应商为:埃克森,熔融指数为2g/10min,2.16kg,190℃);
低密度聚乙烯,牌号为2426K(供应商为:扬子巴斯夫,熔融指数为4g/10min,2.16kg,190℃);
相容剂,EVA(牌号为150W,供应商为:美国杜邦)。
填充粉体,钛白粉与氧化锌按照2:1比例混合,市售。
抗氧剂,受阻酚类抗氧剂(商品名为:抗氧剂-1098和抗氧剂-1010,两者按照1:1比例混合,供应商为:德国BASF公司)。
紫外吸收剂,苯并三唑类光稳定剂(商品名为:UV-P,供应商为:德国BASF公司)。
表1实施例1-4专用料配方(质量份数)
按表1中的配方制备光伏用双层共挤出PO薄膜,制备方法如下:
S1,按照内层和外层原料配比,将内层和外层原料分别经过高速混合机混合,混合时间为5~30分钟,混合转速300~1200rpm;混合后的内层和外层原料分别投入到双螺杆挤出机,进行熔融、分散与挤出造粒,分别得到内层、外层的改性料颗粒;双螺杆挤出机的工作温度为170~210℃,转速为200~800rpm。
S2,将内层、外层的改性料分别投入双层共挤流涎机的两台单螺杆机挤出机内,在170~230℃进行熔化输送,并汇流至流涎模头,模头温度为170~235℃,经模头挤出后拉伸、冷却定型,切边收卷,从而得到所述PO薄膜。
实施例1-4高混机、双螺杆和单螺杆的温度和转速条件见表2。
表2
实施例1-4制备了总厚度50~70um的双层共挤出PO薄膜,与EVA胶膜进行粘结并测试粘结力,测试方法参照GB/T31034-2014中6.9项背板与EVA剥离强度测试。同时,进行层压测试有效绝缘厚度,测试方法为:将贴合PO薄膜的光伏背板裁剪成合适大小,与EVA胶膜叠放后进行层压,中间放置锡焊丝,层压温度为135-145℃,层压后焊丝压入PO薄膜,PO薄膜残余厚度即为本发明中所述有效绝缘厚度。另外,对薄膜样品的耐热性、耐候性进行测试,测试方法为:将实施例1-4制成的样品裁剪成合适大小的试样,放入紫外高温高湿老化试验箱内,试验条件为:试验箱环境温度85±2℃,相对湿度85±5%,UVA波长(320-400nm),UVB波长(280-320nm),其中UVB辐照量为总波段的3%-10%,通过紫外灯管功率和辐照时间计算单位面积辐照量,业内称为湿紫外。对比例为TPE结构中的PE薄膜,测试结果总结见表3:
表3样品1~4的性能测试结果
上述测试结果表明:双层共挤出PO薄膜与白色EVA胶膜以及透明EVA胶膜均有良好的粘接性,经湿紫外辐照老化的耐候性明显优于PE膜,有效绝缘厚度远超PE膜,能够为1500V光伏产品提供更安全的保障。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (9)
1.一种光伏用双层共挤出PO薄膜,其特征在于:具有共挤出形成的内层和外层两层结构,所述内层为改性均聚聚丙烯层,所述外层为改性共聚聚丙烯层。
2.根据权利要求1所述的光伏用双层共挤出PO薄膜,其特征在于:所述内层的厚度为20~40微米,所述外层的厚度为20~40微米,所述PO薄膜总厚度50~70微米。
4.根据权利要求3所述的光伏用双层共挤出PO薄膜,其特征在于:所述均聚聚丙烯和共聚聚丙烯的熔融指数均为5~30g/10min、2.16kg、230℃;所述低密度聚乙烯和线性低密度聚乙烯的熔融指数均为1~10g/10min、2.16kg、190℃。
5.根据权利要求3所述的光伏用双层共挤出PO薄膜,其特征在于:所述抗氧剂为受阻酚类抗氧剂、受阻胺类抗氧剂、亚磷酸酯类抗氧剂、硫酯类抗氧剂中的至少一种。
6.根据权利要求3所述的光伏用双层共挤出PO薄膜,其特征在于:所述紫外吸收剂为水杨酸酯类紫外吸收剂、苯酮类紫外吸收剂、取代丙烯腈类紫外吸收剂、三嗪类紫外吸收剂与受阻胺类紫外吸收剂中的至少一种。
7.根据权利要求3所述的光伏用双层共挤出PO薄膜,其特征在于:所述相容剂为POE、EVA、EAA、EEA、EMAA、EMA、EBA、EPDM中的至少一种。
8.根据权利要求3所述的光伏用双层共挤出PO薄膜,其特征在于:所述填充粉体为硫酸钡、滑石粉、钛白粉、氧化锌、碳酸钙中的至少一种。
9.一种光伏用双层共挤出PO薄膜的制备方法,其特征在于:包括以下步骤,
S1,按照内层和外层原料配比,将内层和外层原料分别经过高速混合机混合后投入到双螺杆挤出机,在170~210℃下进行熔融、分散与挤出造粒,分别得到内层、外层的改性料颗粒;
S2,将内层、外层的改性料分别投入双层共挤流涎机的两台单螺杆机挤出机内,在170~230℃进行熔化输送,并汇流至流涎模头,模头温度为170~235℃,经模头挤出后拉伸、冷却定型,切边收卷,从而得到所述PO薄膜。
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