CN113698854A - 一种无溶剂涂料、一种太阳能电池背板 - Google Patents
一种无溶剂涂料、一种太阳能电池背板 Download PDFInfo
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Abstract
本发明提供的无溶剂涂料,包括含氟聚氨酯树脂、固化剂、助剂、颜填料、活性稀释剂,不含有机溶剂,使用时不会污染环境,通过采用含有羟基的含氟聚氨酯树脂,能够通过羟基与基材层活性基团的反应,提升附着力,由于聚氨酯树脂含氟,使得该涂料电气绝缘性、阻水性和耐候性好,本发明提供的太阳能电池背板,包括基材层和位于基材层表面的涂层,基材层包括位于由PET材料制成的基底层和位于基底层两侧由PET材料和改性树脂制成的改性层,涂层由上述涂料固化形成,固化时,羟基与改性树脂中的活性基团反应,在涂层和改性层之间生成用于附着力的化学共价键,既能降低成本,又能具有好的电气绝缘性好、阻水性和耐候性,还能摒弃有机溶剂,不污染环境。
Description
技术领域
本申请涉及太阳能电池背板技术领域,具体涉及一种用于制作太阳能电池背板的无溶剂涂料及一种太阳能电池背板。
背景技术
太阳能电池背板是对太阳能电池起支撑和保护作用的重要部件,需要具有可靠的电气绝缘性、阻水性和耐候性能。
现有的太阳能电池背板包括复合型和涂布型两大类,复合型的主要代表为杜邦生产的TPT型复合结构背板,由聚酯层和附着在聚酯层上下两侧的氟膜复合而成,如法国专利FR1357492A、中国专利CN206520288U、CN211125672U均公开了此类型的太阳能电池背板,但这类产品工艺复杂、成本高。
涂布型是采用涂料涂布的形式取代复合型中的氟膜,具有制备方便、工艺简单、成本低等优点,但现有的涂料需使用大量有机溶剂,如中国专利CN110885593A、CN107779015B均公开了这类涂料,在制作太阳能电池背板时,虽然有机溶剂能够提供很好的附着力,但也存在易挥发,容易污染环境的缺陷,并且,有机溶剂挥发后还会在涂料中产生水汽通道,影响太阳能电池背板的阻水性和耐候性,若不采用有机溶剂,又难以使涂料附着。
发明内容
本发明的目的是为了克服现有技术的缺陷,提供一种用于制作太阳能电池背板的无溶剂涂料,该涂料不含有机溶剂,使用时不会污染环境,附着力好,电气绝缘性、阻水性和耐候性好,本发明还提供一种使用该涂料制作的太阳能电池背板,该太阳能电池背板的制作工艺简单、成本低、不污染环境,该太阳能电池背板的电气绝缘性好、阻水性好、耐候性好、涂层与基材层的附着力好。
为实现上述目的,本发明提供的技术方案是,无溶剂涂料,用于制作太阳能电池背板,所述无溶剂涂料包括35-50%的含氟聚氨酯树脂、8-15%的固化剂、0.5-5%的助剂、15-40%的颜填料、5-15%的活性稀释剂,所述含氟聚氨酯树脂含有羟基,所述含氟聚氨酯树脂是通过将侧链含氟的羟基聚醚二元醇、聚酯多元醇、脂肪族异氰酸酯、含有羟基的二元醇通过加热逐步聚合反应制得。
优选地,所述聚酯多元醇包括聚己内酯、聚碳酸酯、聚己二酸丁二醇酯、聚二聚酸二元醇酯中的任意一种或其混合物,所述聚酯多元醇的平均分子量为1000-2000。
优选地,所述脂肪族为脂肪族丙烯酸酯聚合物,所述脂肪族丙烯酸酯聚合物由甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸、甲基丙烯酸缩水甘油酯、甲基丙烯酸羟乙酯中的任意一种或其混合物聚合制得。
优选地,所述异氰酸酯的单体包括六亚甲基异氰酸酯、异氟尔酮二异氰酸酯、氢化苯甲基烷二异氰酸酯、环己烷二亚甲基二异氰酸酯中的任意一种或其混合物。
优选地,所述含有羟基的二元醇为二羟甲基丙酸、二羟甲基丁酸中的任意一种或其混合物。
优选地,所述侧链含氟的羟基聚醚二元醇与所述异氰酸酯的摩尔比为0.8-0.95。
优选地,所述颜填料包括金红石型二氧化钛、纳米二氧化钛、纳米二氧化锌、二氧化硅、氧化铝、硫酸钡中的任意一种或其混合物。
优选地,所述助剂包括分散剂、流平剂、消泡剂、润湿剂、抗氧剂、耐水解助剂、催化剂、紫外线吸收剂、光稳定剂。
为实现上述目的,本发明还提供一种太阳能电池背板,包括:
基材层,所述基材层为三层结构,所述基材层包括位于中间的基底层和位于所述基底层上、下侧的改性层;
涂层,所述涂层由涂覆在所述基材层上、下表面的涂料固化形成;
所述基底层由PET材料制成,所述改性层由PET材料和改性树脂制成,所述改性树脂包括聚碳酸酯树脂、聚丙烯酸树脂缩水甘油酯、聚马来酸酐树脂中的任意一种或其混合物;
所述涂料包括上述任意一种无溶剂涂料,在所述涂料固化时,所述含氟聚氨酯树脂中的羟基与所述改性树脂中的活性基团反应,在所述涂层和所述改性层相接触的表面生成用于提高所述涂层和所述基材层之间附着力的化学共价键。
优选地,所述基材层由所述PET材料、所述改性树脂材料通过三层共挤以及双向拉伸工艺制成,所述基底层的厚度为220-250微米,所述改性层的厚度为15-30微米,所述涂层的厚度为5-20微米。
由于上述技术方案的运用,本发明与现有技术相比具有下列优点:
本发明提供的无溶剂涂料,包括35-50%的含氟聚氨酯树脂、8-15%的固化剂、0.5-5%的助剂、15-40%的颜填料、5-15%的活性稀释剂,含氟聚氨酯树脂含有羟基,通过将侧链含氟的羟基聚醚二元醇、聚酯多元醇、脂肪族异氰酸酯、含有羟基的二元醇通过加热逐步聚合反应制得,该涂料不含有机溶剂,使用时不会污染环境,由于羟基的存在,能够通过羟基与基材层上活性基团的反应,提升含氟聚氨酯树脂的附着力,由于含氟聚氨酯树脂的存在,使得该涂料具有较好的电气绝缘性、阻水性和耐候性。
本发明提供的太阳能电池背板,包括三层结构的基材层和由涂覆在基材层上、下表面的涂料固化形成的涂层,基材层包括位于中间的基底层和位于基底层上、下侧的改性层,通过使基底层由PET材料制成,使改性层由PET材料和改性树脂制成,使改性树脂包括聚碳酸酯树脂、聚丙烯酸树脂缩水甘油酯、聚马来酸酐树脂中的任意一种或其混合物,使涂料为上述无溶剂涂料,在涂料固化时,使含氟聚氨酯树脂中的羟基与改性树脂中的活性基团反应,在涂层和改性层相接触的表面生成用于提高涂层和基材层之间附着力的化学共价键,既能够简化制造太阳能光伏背板的工艺,降低成本,又能够具有电气绝缘性好、阻水性好、耐候性好的特性,还能够摒弃有机溶剂的使用,避免环境污染,同时增强涂层与基材层的附着力,延长太阳能电池背板的使用寿命。
附图说明
图1是本发明中太阳能电池背板优选实施例的截面放大示意图。
其中:10.涂层;20.改性层;30.基底层。
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述,以使本发明的优点和特征更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
本发明中太阳能电池背板性能测试按照国家标准《晶体硅太阳能电池组件用绝缘背板GB/T31034-2014》进行,序列老化测试按照IEC63209《光伏组件长期应力测试》标准进行。
本发明中描述的上下方向是指图1中的上下方向。
本发明提供的无溶剂涂料,用于制作太阳能电池背板,该涂料包括35-50%的含氟聚氨酯树脂、8-15%的固化剂、0.5-5%的助剂、15-40%的颜填料、5-15%的活性稀释剂,上述百分比为质量比,含氟聚氨酯树脂含有羟基,含氟聚氨酯树脂是通过将侧链含氟的羟基聚醚二元醇、聚酯多元醇、脂肪族异氰酸酯、含有羟基的二元醇通过加热逐步聚合反应制得。
该涂料不含有机溶剂,使用时不会污染环境,由于羟基的存在,能够通过羟基与基材层上活性基团的反应,提升含氟聚氨酯树脂的附着力,由于含氟聚氨酯树脂的存在,使得该涂料具有较好的电气绝缘性、阻水性和耐候性。
优选地,聚酯多元醇包括聚己内酯、聚碳酸酯、聚己二酸丁二醇酯、聚二聚酸二元醇酯中的任意一种或其混合物,聚酯多元醇的平均分子量为1000-2000。
优选地,脂肪族为脂肪族丙烯酸酯聚合物,脂肪族丙烯酸酯聚合物由甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸、甲基丙烯酸缩水甘油酯、甲基丙烯酸羟乙酯中的任意一种或其混合物聚合制得。
优选地,异氰酸酯的单体包括六亚甲基异氰酸酯、异氟尔酮二异氰酸酯、氢化苯甲基烷二异氰酸酯、环己烷二亚甲基二异氰酸酯中的任意一种或其混合物。
优选地,含有羟基的二元醇为二羟甲基丙酸、二羟甲基丁酸中的任意一种或其混合物。
优选地,侧链含氟的羟基聚醚二元醇与异氰酸酯的摩尔比为0.8-0.95。
优选地,颜填料包括金红石型二氧化钛、纳米二氧化钛、纳米二氧化锌、二氧化硅、氧化铝、硫酸钡中的任意一种或其混合物。
优选地,助剂包括分散剂、流平剂、消泡剂、润湿剂、抗氧剂、耐水解助剂、催化剂、紫外线吸收剂、光稳定剂。
如图1所示,本发明提供的太阳能电池背板,包括基材层,基材层为三层结构,基材层包括位于中间的基底层30和位于基底层30上、下侧的改性层20;
涂层10,涂层10由涂覆在基材层上、下表面的涂料固化形成;
基底层30由PET材料制成,改性层20由PET材料和改性树脂制成,改性树脂包括聚碳酸酯树脂、聚丙烯酸树脂缩水甘油酯、聚马来酸酐树脂中的任意一种或其混合物;
涂料包括上述任意一种无溶剂涂料,在涂料固化时,含氟聚氨酯树脂中的羟基与改性树脂中的活性基团反应,在涂层10和改性层30相接触的表面生成用于提高涂层10和基材层之间附着力的化学共价键。
这样设置的好处在于,既能够简化制造太阳能光伏背板的工艺,降低成本,又能够具有电气绝缘性好、阻水性好、耐候性好的特性,还能够摒弃有机溶剂的使用,避免环境污染,同时增强涂层与基材层的附着力,延长太阳能电池背板的使用寿命。
优选地,基材层由PET材料、改性树脂材料通过三层共挤以及双向拉伸工艺制成,基底层30的厚度为220-250微米,改性层20的厚度为15-30微米,涂层10的厚度为5-20微米。
下面以图1中太阳能电池背板的制作为例进行说明。
第一步,制备基材层,包括以下步骤:
a.将100份PET聚酯粒料在140℃干燥后,与5份聚碳酸酯树脂、0.2份抗水解剂、0.2份抗氧剂、7份丙烯酸羟乙酯-丙烯酸丁酯-甲基丙烯酸缩水甘油酯、1份钛白粉,混合后进行造粒;
b. 将喂料速度调整为5rpm,将螺杆转速调整为20rpm,将双螺杆挤出造粒的温度调整为245OC—265 OC,制得改性PET粒料;
c. 将改性PET粒料与普通增粘PET粒料,经过三层共挤流延挤出铸片、双向拉伸,制得具有三层结构的基材层,该基材层包括位于中间的基底层30和位于基底层上、下侧的改性层20。
采用这种方式制成的基材层,不仅上下表面大量活性基团,并且,由于改性层与基底层的主要成分均为PET,使得改性层与基底层的连接非常牢固,相当于一个整体。
第二步,制备涂料,包括两种配方:
第一种配方如下:
含氟改性聚氨酯树脂45g、金红石型钛白粉30g、分散剂 1g、聚碳化二亚胺固化剂10g、抗氧剂2g、附着力促进剂 2g、紫外吸收剂1g、光稳定剂0.3g、活性稀释剂15g、消光粉4g。
第二种配方如下:
含氟改性聚氨酯树脂45g、金红石型钛白粉30g、分散剂1g、HDI三聚体固化剂10g、抗氧剂2g、附着力促进剂2g、纳米二氧化锌2g、活性稀释剂15g、消光粉5g;其中,含氟改性聚氨酯树脂按以下方式制备:
2,3,4,5-四氟-1,6-己二醇、1000分子量聚碳酸酯二元醇、分子量2000的聚醚二元醇N220、六亚甲基二异氰酸酯(HDI)按物质的量0.4:2:2:2.2进行预聚,制得含氟改性聚氨酯树脂。
第三步,制作太阳能电池背板,包括两种实施例:
实施例1
将第一种配方制备的涂料涂布于第一步得到的基材层上,150℃烘烤10min,即制得太阳能电池背板。
实施例2
将第二种配方制得的涂料涂布于第一步得到的基材层上,150℃烘干10min,再55℃熟化2天,即制得无溶剂耐候太阳能背板。
为便于比较,还准备了两种对比例:
对比例1
将第一种配方制得的涂料涂布在市售的普通PET基材上,150℃烘烤10min,制得对比例1的太阳能电池背板。
对比例2
购买市售的KPC结构太阳能电池背板作为对比例2的太阳能电池背板。
下面为实施例1、2和对比例1、2在恒定湿热(85℃,85%相对湿度)条件下,长期老化测试结果的对比。
下面为实施例1、2和对比例1、2涂层性能测试结果。
根据以上两组对比可以看出,本发明提供的无溶剂涂料,附着力好、落沙耐磨性好、剥离强度高、序列老化测试中外观表现好、耐候性能优异,能够对基材层起到良好的保护作用,与封装胶膜具有优异的粘结性能,适用于太阳能电池背板的制作,本发明提供的太阳能电池背板,涂层与基材层的附着力性能优异,耐候性好,适合在温湿度变化大、光照充足、紫外线强烈的地方使用。
上述实施例只为说明本发明的技术构思及特点,其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施,并不能以此限制本发明的保护范围,凡根据本发明精神实质所作的等效变化或修饰,都应涵盖在本发明的保护范围之内。
Claims (10)
1.一种无溶剂涂料,用于制作太阳能电池背板,其特征在于:所述无溶剂涂料包括35-50%的含氟聚氨酯树脂、8-15%的固化剂、0.5-5%的助剂、15-40%的颜填料、5-15%的活性稀释剂,所述含氟聚氨酯树脂含有羟基,所述含氟聚氨酯树脂是通过将侧链含氟的羟基聚醚二元醇、聚酯多元醇、脂肪族异氰酸酯、含有羟基的二元醇通过加热逐步聚合反应制得。
2.根据权利要求1所述的无溶剂涂料,其特征在于:所述聚酯多元醇包括聚己内酯、聚碳酸酯、聚己二酸丁二醇酯、聚二聚酸二元醇酯中的任意一种或其混合物,所述聚酯多元醇的平均分子量为1000-2000。
3.根据权利要求1所述的无溶剂涂料,其特征在于:所述脂肪族为脂肪族丙烯酸酯聚合物,所述脂肪族丙烯酸酯聚合物由甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸、甲基丙烯酸缩水甘油酯、甲基丙烯酸羟乙酯中的任意一种或其混合物聚合制得。
4.根据权利要求1所述的无溶剂涂料,其特征在于:所述异氰酸酯的单体包括六亚甲基异氰酸酯、异氟尔酮二异氰酸酯、氢化苯甲基烷二异氰酸酯、环己烷二亚甲基二异氰酸酯中的任意一种或其混合物。
5.根据权利要求1所述的无溶剂涂料,其特征在于:所述含有羟基的二元醇为二羟甲基丙酸、二羟甲基丁酸中的任意一种或其混合物。
6.根据权利要求1所述的无溶剂涂料,其特征在于:所述侧链含氟的羟基聚醚二元醇与所述异氰酸酯的摩尔比为0.8-0.95。
7.根据权利要求1所述的无溶剂涂料,其特征在于:所述颜填料包括金红石型二氧化钛、纳米二氧化钛、纳米二氧化锌、二氧化硅、氧化铝、硫酸钡中的任意一种或其混合物。
8.根据权利要求1所述的无溶剂涂料,其特征在于:所述助剂包括分散剂、流平剂、消泡剂、润湿剂、抗氧剂、耐水解助剂、催化剂、紫外线吸收剂、光稳定剂。
9.一种太阳能电池背板,包括:
基材层,所述基材层为三层结构,所述基材层包括位于中间的基底层和位于所述基底层上、下侧的改性层;
涂层,所述涂层由涂覆在所述基材层上、下表面的涂料固化形成;
其特征在于:
所述基底层由PET材料制成,所述改性层由PET材料和改性树脂制成,所述改性树脂包括聚碳酸酯树脂、聚丙烯酸树脂缩水甘油酯、聚马来酸酐树脂中的任意一种或其混合物;
所述涂料包括权利要求1-8中任意一项所述的无溶剂涂料,在所述涂料固化时,所述含氟聚氨酯树脂中的羟基与所述改性树脂中的活性基团反应,在所述涂层和所述改性层相接触的表面生成用于提高所述涂层和所述基材层之间附着力的化学共价键。
10.根据权利要求9所述的太阳能电池背板,其特征在于:所述基材层由所述PET材料、所述改性树脂材料通过三层共挤以及双向拉伸工艺制成,所述基底层的厚度为220-250微米,所述改性层的厚度为15-30微米,所述涂层的厚度为5-20微米。
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