CN112721374A - 一种光伏背板基材保护用耐低温聚丙烯薄膜及其制作工艺 - Google Patents
一种光伏背板基材保护用耐低温聚丙烯薄膜及其制作工艺 Download PDFInfo
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Abstract
本发明涉及一种光伏背板基材保护用耐低温聚丙烯薄膜及其制作工艺,本发明的一种光伏背板基材保护用耐低温聚丙烯薄膜,该薄膜为由外表层、芯层和内表层依次组成的三层结构,薄膜中间层为芯层,所述内表层为电晕处理层,所述外表层为未处理层;所述中间层即芯层的组分为1%~3%wt抗静电母料、1%~3%wt抗UV母料、10%~30%wt耐低温母料和60%~89%wt均聚聚丙烯;所述内表层的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料、1%~3%wt抗静电母料和82%~91%wt均聚聚丙烯;所述外表层的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料和85%~92%wt均聚聚丙烯。
Description
技术领域
本发明涉及薄膜领域,具体是涉及一种光伏背板基材保护用耐低温聚丙烯薄膜及其制作工艺。
背景技术
光伏组件一般布置在屋顶、旷野甚至沙漠地区,环境较为恶劣,温差较大,因此,需要对(光伏)背板基材进行保护。一般情况下(即现有的),在行业中使用BOPP或BOPET薄膜作为保护膜,但是由于BOPP和BOPET玻璃化转变温度均较高,耐低温性能较差,在使用过程中容易出现两端翅起,甚至起皮、起泡问题。
发明内容
为避免现有技术所存在的不足之处,本发明的目的在于提供一种具有耐低温、抗UV,且晶点、杂质少,透明度高,印刷性能和抗撕裂性优异的聚丙烯保护薄膜及其制作工艺,其具有普通双向拉伸聚丙烯薄膜优异的物理机械性能以及光学性能的同时,通过降低聚丙烯分子量并添加一定比例的耐低温母料,一定程度上降低薄膜的挺度,赋予薄膜柔软度和服帖性,并且使用过程中不会产生翘曲、回缩等现象,其拉伸强度大,抗撕裂性能优异,不会产生剥离和卷绕困难的问题。
本发明通过以下技术方案实现上述目的:一种光伏背板基材保护用耐低温聚丙烯薄膜,该薄膜为由外表层、芯层和内表层依次组成的三层结构,薄膜中间层为芯层,所述内表层为电晕处理层,所述外表层为未处理层;
所述中间层即芯层的组分为1%~3%wt抗静电母料、1%~3%wt抗UV母料、10%~30%wt耐低温母料和60%~89%wt均聚聚丙烯;
所述内表层的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料、1%~3%wt抗静电母料和82%~91%wt均聚聚丙烯;
所述外表层的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料和85%~92%wt均聚聚丙烯。
进一步的,所述外表层与内表层厚度均为0.5~5μm。
再进一步的,所述外表层、芯层、内表层厚度比例范围为:1:(10~20):(2~3);所述内表层与光伏背板基材贴附。
再进一步的,所述抗静电母料为单硬酸甘油脂、N,N-二(2-羟基乙基)十八胺、脂肪醇聚醚酰胺与均聚聚丙烯混炼物。
再进一步的,所述的耐低温母料包括:3%~15%wt乙烯丙烯共聚物、3%~15%wt乙烯丁烯共聚物、3%~15%wt丙烯丁烯共聚物、10%~25%wt低密度聚乙烯和30%~81%线性低密度聚乙烯。
一种光伏背板基材保护用耐低温聚丙烯薄膜的制备方法,包括以下步骤:
a、芯层原料由均聚聚丙烯、抗静电母料、抗UV母料、耐低温母料经过配比和干燥送到主挤出机中加热成熔融状态;外表层原料由抗粘连母料、抗UV母料、耐低温母料、均聚聚丙烯经过配比在一台辅助挤出机中加热熔融;内表层原料由抗粘连母料、抗静电母料、抗UV母料、耐低温母料、均聚聚丙烯经过配比在一台辅助挤出机中加热熔融;上述三种熔体分别经过350目~400目过滤网过滤,在三层结构模头中汇合挤出,模头温度为235℃~242℃;
b、上述熔体从模头挤出后,用压缩空气贴附到20℃~30℃激冷辊上急冷形成铸片,之后进入水浴冷却,用压缩空气对冷却后的铸片进行除水;
c、铸片经过120℃~140℃预热,在120℃~130℃下纵向延伸,延伸倍率在2.0~3.0;
d、在纵向拉伸后得到的薄膜进行横向拉伸,在横向拉伸前以182℃~167℃进行预热,在153~160℃下进行横向拉伸,155℃~165℃热定型,拉伸倍率为4.0~6.0;
e、步骤d得到的薄膜经过风冷进入牵引系统展平,并对内表面进行电晕处理和收卷;
f、经过时效处理后,分切、包装制成成品薄膜。
本发明的有益效果:本发明涉及一种光伏背板基材保护用耐低温聚丙烯薄膜及其制作工艺,更具体地说是涉及一种作为光伏背板基材保护用具有耐低温、抗UV,且晶点、杂质少,透明度高,印刷性能和抗撕裂性优异的聚丙烯保护薄膜及其制作工艺,使被保护的产品(光伏背板基材)在生产加工、运输、贮存和使用过程中不受污染、腐蚀、划伤、保护原有的光洁亮泽的表面,从而提高产品(光伏背板基材)的质量及市场竞争力。
附图说明
以下结合附图和实施例对本发明作进一步详细说明,并不因此将本发明限制在所述的实施例范围中。
图1为本发明的一种光伏背板基材保护用耐低温聚丙烯薄膜的三层构造示意图;
图中1为外表层,2为芯层,3为内表层。
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。
本发明公开了一种光伏背板基材保护用耐低温聚丙烯薄膜,是一种光伏背板基材保护用耐低温、抗紫外聚丙烯薄膜,该薄膜为由外表层1、芯层2和内表层3依次组成的三层结构,薄膜中间层为芯层2,所述内表层3为电晕处理层,所述外表层1为未处理层;本发明具有很好的低温柔软度,可在摄氏零下50℃保持较好的柔软度,并能有效阻隔紫外线,且物理性能、光学性能、印刷性能优异,抗撕裂性能好,静电小,最大限度的保护光伏背板基材,加工工艺简单等优点。
具体的,本发明的一种光伏背板基材保护用耐低温聚丙烯薄膜,该薄膜为由中间层、内表层3和外表层1依次组成的三层结构,所述中间层为芯层2,所述内表层3为电晕处理层,所述外表层1为未处理层;
所述中间层即芯层2的(质量)组分为1%~3%wt抗静电母料、1%~3%wt抗UV母料、10%~30%wt耐低温母料和60%~89%wt均聚聚丙烯;
所述内表层3的(质量)组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料、1%~3%wt抗静电母料和82%~91%wt均聚聚丙烯;
所述外表层1的(质量)组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料和85%~92%wt均聚聚丙烯。
进一步的,本发明薄膜外表层1与内表层3厚度均为0.5~5μm,进一步的,外表层1、芯层2、内表层3厚度比例范围为:1:(10~20):(2~3);所述内表层3与光伏背板基材贴附。
进一步的,所述抗静电母料为单硬酸甘油脂、N,N-二(2-羟基乙基)十八胺、脂肪醇聚醚酰胺与均聚聚丙烯混炼物。
进一步的,所述的耐低温母料包括(以下质量百分比):3%~15%wt乙烯丙烯共聚物、3%~15%wt乙烯丁烯共聚物、3%~15%wt丙烯丁烯共聚物、10%~25%wt低密度聚乙烯和30%~81%线性低密度聚乙烯。
本发明提供的一种光伏背板基材保护用耐低温聚丙烯薄膜的制造工艺,其采用下述步骤如下:
b、芯层2原料由均聚聚丙烯、抗静电母料、抗UV母料、耐低温母料经过(前述)配比和干燥送到主挤出机中加热成熔融状态;外表层1原料由抗粘连母料、抗UV母料、耐低温母料、均聚聚丙烯经过(前述)配比在一台辅助挤出机中加热熔融;内表层3原料由抗粘连母料、抗静电母料、抗UV母料、耐低温母料、均聚聚丙烯经过(前述)配比在一台辅助挤出机中加热熔融;上述(三种)熔体分别(单独)经过350目~400目过滤网过滤,在三层结构模头中汇合挤出,模头温度为235℃~242℃;(这里解释下,本发明薄膜是三层的分层结构,即将上述三种熔体分别单独过滤,然后在模头汇合,这样汇合之后还是三层的分层结构)
b、上述熔体从模头挤出后,用压缩空气贴附到20℃~30℃激冷辊上急冷形成铸片,之后进入水浴冷却,用压缩空气对冷却后的铸片进行除水;
c、铸片经过120℃~140℃预热,在120℃~130℃下纵向延伸,延伸倍率在2.0~3.0;
d、在纵拉(即纵向拉伸)后得到的薄膜进行横拉(即横向拉伸),在横向拉伸前以182℃~167℃进行预热,在153~160℃下进行(横向)拉伸,155℃~165℃热定型,拉伸倍率为4.0~6.0;
e、步骤d得到的薄膜经过风冷进入牵引系统展平,并对内表面3进行电晕处理和收卷;
f、经过时效处理后,分切、包装制成成品(薄膜)。
本发明的有益效果:采用本发明工艺制作的薄膜具有良好的耐低温性能,同时具体抗UV,不易老化,使用寿命长的特性,还具有晶点、杂质少,透明度高,印刷性能和抗撕裂性优异等特点,使被保护的产品(光伏背板基材)在生产加工、运输、贮存和使用过程中不受污染、腐蚀、划伤,保护原有的光洁亮泽的表面,从而提高产品的质量及市场竞争力。
下面给出本发明的一个最优的实施例:
优选的芯层2、内表层3和外表层1的配方如下:
芯层2即中间层的组分为3%wt抗静电母料、3%wt抗UV母料、30%wt耐低温母料和64%~89%wt均聚聚丙烯;
内表层3的组分为5%wt抗粘连母料、3%wt抗UV母料、10%wt耐低温母料、3%wt抗静电母料和79%wt均聚聚丙烯;
外表层1的组分为5%wt抗粘连母料、3%wt抗UV母料、10%wt耐低温母料和82%wt均聚聚丙烯。
上述构造配方按如下生产工艺进行生产:
a、芯层2原料由均聚聚丙烯、抗静电母料、抗UV母料、耐低温母料经过上述配比和干燥送到主挤出机中加热成熔融状态;外表层1原料由抗粘连母料、抗UV母料、耐低温母料、均聚聚丙烯经过上述配比在一台辅助挤出机中加热熔融;内表层3原料由抗粘连母料、抗静电母料、抗UV母料、耐低温母料、均聚聚丙烯经过上述配比在一台辅助挤出机中加热熔融;上述(三种)熔体分别(单独)经过400目过滤网过滤,在三层结构模头中汇合挤出,模头温度为242℃;
b、上述熔体从模头挤出后,用压缩空气贴附到20℃激冷辊上急冷形成铸片,之后进入水浴冷却,用压缩空气对冷却后的铸片进行除水;
c、铸片经过125℃预热,在122℃下纵向延伸,延伸倍率在2.5;
d、在纵拉(即纵向拉伸)后得到的薄膜进行横拉(即横向拉伸),在横向拉伸前以178℃进行预热,在153℃下进行(横向)拉伸,162℃热定型,拉伸倍率为5.2;
e、上述步骤得到的薄膜经过风冷进入牵引系统展平,并对内表面3进行电晕处理和收卷;
f、经过时效处理后,分切、包装制成成品(薄膜)。
采用上述方法制成的薄膜,沿纵向取250mm、宽100mm试样,将试样两表面及长400mm、宽200mm不锈钢平板上均匀撒布一层滑石粉,将试样沿纵向对折,首端重叠在一起(形成一个扁环状),在此状态下停放3min,用分度值为1mm的刻度尺测量试样两边相对于(不锈钢)平板的最大高度,此高度即表征了薄膜的柔软度,使用上述方法制成的薄膜柔软度测试数值满足下表要求。
35μm成品性能指标如下:
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 (6)
1.一种光伏背板基材保护用耐低温聚丙烯薄膜,其特征在于,该薄膜为由外表层(1)、芯层(2)和内表层(3)依次组成的三层结构,薄膜中间层为芯层(2),所述内表层(3)为电晕处理层,所述外表层(1)为未处理层;
所述中间层即芯层(2)的组分为1%~3%wt抗静电母料、1%~3%wt抗UV母料、10%~30%wt耐低温母料和60%~89%wt均聚聚丙烯;
所述内表层(3)的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料、1%~3%wt抗静电母料和82%~91%wt均聚聚丙烯;
所述外表层(1)的组分为3%~5%wt抗粘连母料、1%~3%wt抗UV母料、5%~10%wt耐低温母料和85%~92%wt均聚聚丙烯。
2.根据权利要求1所述的一种光伏背板基材保护用耐低温聚丙烯薄膜,其特征在于:所述外表层(1)与内表层(3)厚度均为0.5~5μm。
3.根据权利要求2所述的一种光伏背板基材保护用耐低温聚丙烯薄膜,其特征在于:所述外表层(1)、芯层(2)、内表层(3)厚度比例范围为:1:(10~20):(2~3);所述内表层(3)与光伏背板基材贴附。
4.根据权利要求1或2或3所述的一种光伏背板基材保护用耐低温聚丙烯薄膜,其特征在于:所述抗静电母料为单硬酸甘油脂、N,N-二(2-羟基乙基)十八胺、脂肪醇聚醚酰胺与均聚聚丙烯混炼物。
5.根据权利要求1或2或3所述的一种光伏背板基材保护用耐低温聚丙烯薄膜,其特征在于:所述的耐低温母料包括:3%~15%wt乙烯丙烯共聚物、3%~15%wt乙烯丁烯共聚物、3%~15%wt丙烯丁烯共聚物、10%~25%wt低密度聚乙烯和30%~81%线性低密度聚乙烯。
6.根据权利要求1-5中任意一项一种光伏背板基材保护用耐低温聚丙烯薄膜的制备方法,其特征在于,包括以下步骤:
a、芯层(2)原料由均聚聚丙烯、抗静电母料、抗UV母料、耐低温母料经过配比和干燥送到主挤出机中加热成熔融状态;外表层(1)原料由抗粘连母料、抗UV母料、耐低温母料、均聚聚丙烯经过配比在一台辅助挤出机中加热熔融;内表层(3)原料由抗粘连母料、抗静电母料、抗UV母料、耐低温母料、均聚聚丙烯经过配比在一台辅助挤出机中加热熔融;上述三种熔体分别经过350目~400目过滤网过滤,在三层结构模头中汇合挤出,模头温度为235℃~242℃;
b、上述熔体从模头挤出后,用压缩空气贴附到20℃~30℃激冷辊上急冷形成铸片,之后进入水浴冷却,用压缩空气对冷却后的铸片进行除水;
c、铸片经过120℃~140℃预热,在120℃~130℃下纵向延伸,延伸倍率在2.0~3.0;
d、在纵向拉伸后得到的薄膜进行横向拉伸,在横向拉伸前以182℃~167℃进行预热,在153~160℃下进行横向拉伸,155℃~165℃热定型,拉伸倍率为4.0~6.0;
e、步骤d得到的薄膜经过风冷进入牵引系统展平,并对内表面(3)进行电晕处理和收卷;
f、经过时效处理后,分切、包装制成成品薄膜。
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