CN114823956A - 太阳能电池轻质组件用复合材料及其制备方法 - Google Patents
太阳能电池轻质组件用复合材料及其制备方法 Download PDFInfo
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Abstract
本发明属于太阳能电池轻质组件技术领域,具体涉及一种太阳能电池轻质组件用复合材料及其制备方法,包括以下步骤:步骤S1,将甲基丙烯酸甲酯与紫外吸收剂、光稳定剂预混,然后加入引发温度依次升高的第一引发剂、第二引发剂和第三引发剂搅拌均匀,并在引发温度各引发剂依次反应,真空脱泡后制得预混树脂;步骤S2,将所述预混树脂涂布在耐候承载膜上,与纤维编织布复合,所述纤维编织布的另外一面复合离型膜,所述预混树脂充分浸润所述纤维编织布后制得太阳能电池轻质组件用复合材料;通过在浸润甲基丙烯酸甲酯单体中引入不同引发温度的引发剂,使MMA逐步均匀交联,提高了太阳能电池轻质组件的抗冲击性能。
Description
技术领域
本发明属于太阳能电池轻质组件技术领域,具体涉及一种太阳能电池轻质组件用复合材料及其制备方法。
背景技术
目前,随着能源短缺,气候排放等严峻问题的凸显,世界各国越来越关注清洁、无污染的可再生能源,以太阳能作为一种绿色的可再生能源的光伏组件得到了大规模的应用。现有技术中,光伏组件通常通过钢化玻璃和电池片层压后,以铝框装框,并将边缘部以硅胶密封而成。然而,上述光伏组件由于钢化玻璃和铝框等的缘故,重量一般较大,对于无法承重的屋面,该光伏组件无法使用。
有开发轻质组件,用透明背板替代玻璃,重量大幅减轻,但是前板的透光率比玻璃降低很多,发电效率减少,同时耐冲击性能大幅下降,受到冰雹的冲击后电池片发生隐裂,从而导致组件受损,影响使用寿命。
发明内容
本发明提供了一种太阳能电池轻质组件用复合材料及其制备方法,以解决当前太阳能电池组件前板的耐冲击性能不足的缺陷。
为了解决上述技术问题,本发明提供了一种太阳能电池轻质组件用复合材料的制备方法,包括以下步骤:步骤S1,将甲基丙烯酸甲酯与紫外吸收剂、光稳定剂预混,然后加入引发温度依次升高的第一引发剂、第二引发剂和第三引发剂搅拌均匀,并在引发温度各引发剂依次反应,真空脱泡后制得预混树脂;步骤S2,将所述预混树脂涂布在耐候承载膜上,与纤维编织布复合,所述纤维编织布的另外一面复合离型膜,所述预混树脂充分浸润所述纤维编织布后制得太阳能电池轻质组件用复合材料。
又一方面,本发明还提供了一种太阳能电池轻质组件用复合材料,包括:耐候承载膜;纤维编织布;所述纤维编织布充分浸润步骤S1所制备的预混树脂后交联固化。
第三方面,本发明还提供了一种太阳能电池轻质组件,包括:增强高透前板、封装胶膜、电池片、封装胶膜、增强背板;其增强高透前板和/或增强背板采用如上所述的太阳能电池轻质组件用复合材料。
本发明的有益效果是,本发明的太阳能电池轻质组件用复合材料,通过在浸润甲基丙烯酸甲酯单体中引入不同引发温度的引发剂,使MMA逐步均匀交联,同时在温度升高过程中新加入反应的引发剂都能够在其引发温度区间的低温环境下尽可能多的发生交联以避免在高温环境下形成气泡,得到交联度更高,韧性更强的材料,提高了太阳能电池轻质组件的抗冲击性能。
本发明的其他特征和优点将在随后的说明书中阐述,并且,部分地从说明书中变得显而易见,或者通过实施本发明而了解。
为使本发明的上述目的、特征和优点能更明显易懂,下文特举较佳实施例,并配合所附附图,作详细说明如下。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案,下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图是本发明的一些实施方式,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1是本发明的太阳能电池轻质组件用复合材料的结构示意图;
图2是本发明的太阳能电池轻质组件的结构示意图;
图3是本发明的太阳能电池轻质组件用复合材料的实施例4抗冲击性能效果图;
图4是本发明的太阳能电池轻质组件用复合材料的对比例1抗冲击性能效果图;
图5是本发明的太阳能电池轻质组件用复合材料的对比例2抗冲击性能效果图。
图中:
耐候承载膜1、纤维编织布2;
增强高透前板100、封装胶膜200、电池片300、增强背板400。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合附图对本发明的技术方案进行清楚、完整地描述,显然,所描述的实施例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。
为了提高太阳能电池轻质组件前板的耐候性以及抗冲击性能,常采用在前板的外层膜为氟膜,其中ETFE(乙烯四氟乙烯),PVDF(聚偏氟乙烯),PVF(聚氟乙烯)或者耐候PET膜以及氟涂层。同时通过纤维编织布浸润树脂后提高整体前板刚性,浸润的树脂一般包括聚酯不饱和树脂、丙烯酸树脂、环氧树脂等,但是聚酯树脂耐水解性能差,环氧树脂容易黄变,丙烯酸树脂韧性不足。
为了解决上述技术问题,本发明还提供了一种太阳能电池轻质组件用复合材料的制备方法,包括以下步骤:步骤S1,将甲基丙烯酸甲酯与紫外吸收剂、光稳定剂预混,然后加入引发温度依次升高的第一引发剂、第二引发剂和第三引发剂搅拌均匀,并在引发温度各引发剂依次反应,真空脱泡后制得预混树脂;步骤S2,将所述预混树脂涂布在耐候承载膜上,与纤维编织布复合,所述纤维编织布的另外一面复合离型膜,所述预混树脂充分浸润所述纤维编织布后制得太阳能电池轻质组件用复合材料。
在本实施例中,具体的,将甲基丙烯酸甲酯单体置于搅拌桶中,加入紫外吸收剂、光稳定剂,高速分散15min,再加入引发剂慢速搅拌5min,真空脱泡后制得预混树脂,为防止单体挥发,搅拌时搅拌桶可以使用夹套冷却或密闭。
在本实施例中,具体的,所述第一引发剂、第二引发剂和第三引发剂分别对应的引发温度分别是55℃~65℃、60℃~80℃和70℃~100℃。
也就是说,本发明采用复合引发剂加入到浸润甲基丙烯酸甲酯单体中,三种引发剂具有不同的引发温度,能够使得MMA逐步均匀交联,并且选择引发温度在55℃~65℃、60℃~80℃和70℃~100℃,上述引发温度区间的引发剂,能够使MMA在上述三个引发温度区间的低温环境下尽可能多的发生交联,而在后续温度重叠段由下一阶段的引发剂抢夺游离自由基,以避免在当前温度区间的后半段高温环境下形成气泡,从而得到了交联度更高,韧性更强的材料,大大地提高了太阳能电池轻质组件前板的抗冲击性能。
其中在本实施例中引发温度在55℃~60℃的引发剂可以但不限于选择含有偶氮二异庚腈ABVN的引发剂;引发温度在60℃~80℃的引发剂可以但不限于选择含有偶氮二异丁腈AIBN的引发剂;引发温度在80℃~100℃的引发剂可以但不限于选择含有过氧化苯甲酰BPO的引发剂。
在本实施例中,具体的,所述步骤S2中将所述耐候承载膜进行电晕处理后再涂布预混树脂,耐候承载膜进行电晕处理后膜材表面的化学键断裂而降解,增加了其表面粗糙度和表面积,能够提高耐候承载膜表面的附着性,提升预混树脂与耐候承载膜的连接强度。进一步地,预混树脂充分浸润复合离型膜后制得增强高透前板。
在本实施例中,具体的,所述预混树脂中各组分的质量份数为:甲基丙烯酸甲酯单体:80~98份;紫外吸收剂:0.1~1份;光稳定剂:0.1~2份;含有偶氮二异庚腈ABVN的引发剂:2~3份;含有偶氮二异丁腈AIBN的引发剂:1~2份;含有过氧化苯甲酰BPO的引发剂:0.5~1份。通过甲基丙烯酸甲酯与复合引发剂按一定比例复配,能够使得MMA交联均匀,得到符合性能要求的材料。过少的引发剂的使用会使得MMA交联不均匀或者交联不充分,过多的引发剂的使用会使得MMA过度交联,影响材料的机械性能。
具体的,所述甲基丙烯酸甲酯单体为ELIUM150,188,191,351,445,591,C595,C195中的一种或多种;所述紫外光吸收剂为CYASORB UV-5411;所述光稳定剂为低聚物受阻胺光稳定剂CYASORB UV-3346;所述含有偶氮二异庚腈ABVN的引发剂为杜邦科慕VAZO52、含有偶氮二异丁腈AIBN的引发剂为杜邦科慕VAZO64、含有过氧化苯甲酰BPO的引发剂为诺力昂CH50X;所述纤维编织布为:巨石2116、1506、7628、7630、7667。
又一方面,如图1所示,本发明提供了一种太阳能电池轻质组件用复合材料,包括:耐候承载膜;纤维编织布;所述纤维编织布充分浸润步骤S1所制备的预混树脂后交联固化。
在本实施例中,可选的,所述耐候承载膜的厚度为25~300μm,如25μm、50μm、75um、100um、125um、188μm、250μm;所述纤维编织布的克重为40~600g/m2,如48g/m2,165g/m2,210g/m2,234g/m2,300g/m2,400g/m2,500g/m2;所述预混树脂浸润克重为50~800g/m2,如50g/m2,75g/m2,100g/m2,165g/m2,210g/m2,150g/m2,300g/m2,400g/m2,500g/m2。
在本实施例中,可选的,所述耐候承载膜包括:ETFE、PVDF、PVF、耐候PET中的任意一种;所述纤维编织布包括无机纤维编织布和有机纤维编织布中的任意一种或多种;其中所述有机纤维编织布包括涤纶、锦纶、腈纶、氨纶中的一种或多种;所述无机纤维编织布包括玻璃纤维、石英玻璃纤维、陶瓷纤维、碳纤维中的一种或多种。
又一方面,如图2所示,本发明还提供了一种太阳能电池轻质组件,包括:增强高透前板、封装胶膜、电池片、封装胶膜、增强背板;其增强高透前板和/或增强背板采用如上所述的太阳能电池轻质组件用复合材料;也就是说,该太阳能电池轻质组件的前板具有优异的抗冲击性能,在恶劣天气环境中适应性高,能够提高太阳能电池轻质组件的使用寿命,而在作为太阳能背板使用时仅需添加透明或有色颜料。
实施例1
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入2质量份数杜邦科慕VAZO52,1质量份数杜邦科慕VAZO64,0.5质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
实施例2
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入2.3质量份数杜邦科慕VAZO52,1.5质量份数杜邦科慕VAZO64,0.8质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
实施例3
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入2.8质量份数杜邦科慕VAZO52,1.6质量份数杜邦科慕VAZO64,0.7质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
实施例4
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入3质量份数杜邦科慕VAZO52,2质量份数杜邦科慕VAZO64,1质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
对比例1
羟基丙烯酸树脂100份,邻苯二甲酸酐固化剂10份,聚酰胺蜡分散剂2份,混合为丙烯酸树脂粉末涂料,丙烯酸粉末涂料涂覆在纤维布上的单位面积重量为315g/m2;将玻纤布涂布后与PVDF膜120~150℃热压,制得复合板材。
对比例2
以F型环氧树脂的质量份为基准,在100L反应釜中,加入10质量份丙酮,升温至40~60℃,然后边搅拌边加入100质量份F46(环氧值0.46)、10质量份E51(环氧值0.51)、13质量份端羧基丁氰橡胶充分搅拌30分钟,即制得环氧树脂组合物。
采用溶液浸胶法经连续浸渍、烘干和收卷工序得到环氧/玻纤预浸料。玻纤克重选择210g,采用压机热压工艺在0.5MPa/130℃条件固化得到环氧/玻纤复增强材料。
对比例3
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入2质量份数杜邦科慕VAZO52,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
对比例4
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入2质量份数杜邦科慕VAZO64,1质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
对比例5
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入1质量份数杜邦科慕VAZO52,2质量份数诺力昂CH50X,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
对比例6
取94.5质量份数甲基丙烯酸甲酯倒入搅拌桶,搅拌桶内加入1质量份数紫外吸收剂,再加入1.5质量份数光稳定剂,转速1000rpm搅拌10分钟,使紫外吸收剂以及光稳定剂分散均匀,之后降低转速到200rpm,再加入1质量份数杜邦科慕VAZO52,2质量份数杜邦科慕VAZO64,搅拌5min,真空除泡后制得预混树脂。
将混合树脂涂覆在电晕后的PVDF膜上,再与玻纤编织布复合,其中所述PVDF膜厚度25um,树脂涂布量200g/m2,编织布克重为210g/m2。在真空烘箱烘干20分钟后制得高透前板。
将各实施例及对比例中的各原料汇总于表1。
表1各实施例及对比例中原料组成
对各实施例及各对比例中制得的太阳能电池前板进行相关性能,并将测试数据汇总于表2。
表2各实施例及对比例中制得前板的性能数据
由表2中数据可知,各实施例中制得的太阳能电池轻质组件前板,较各对比例中制得的太阳能电池轻质前板具有更好的透光率和更高的抗冲击性能;具体如图3所示,本发明的实施例4所制得的太阳能电池前板在双85处理后进行高空坠物测试的损伤区为中间的浅色砸痕,损伤面积小损伤程度轻;而现有技术的对比例1与对比例2在双85处理后进行高空坠物测试的损伤区如图4和图5所示,出现了大面积的深度砸痕,可见本发明的太阳能电池轻质组件用复合材料具有有优异的耐冲击性能。
同时,根据实施例1-4数据可知,因三级交联,且因引发温度不同的引发剂使得三次交联均可在对应引发温度区间的早期进行,即前一种引发剂需在其引发温度区间的高温环境下交联完成的部分将由后一种引发剂在其引发温度区间的相对较低的温度下进行,大大降低了因高温环境而造成的气泡产生,同时也大大提高了交联度,故而在第一级引发温度区间的环境下投入更多量的起始引发温度的引发剂可以获得性能更为优异的轻质组件用复合材料。
值得关注的是,相较于对比例3-6中的单次交联和二次交联,通过不同起始引发温度的引发剂实时三次交联,所获得的太阳能电池轻质组件前板的耐冲击性能存在有实质性的提升,这在于MMA逐步均匀交联,反应过程中产生气泡少,且后续引发剂的交联反应能够对前期交联在进入反应末期时的负面效果起到较好的效果,而仅加入一种或两种交联剂虽可双85试验对耐冲击性能的衰减影响,但轻质组件前板原本的耐冲击性能明显逊于本发明的三次交联后的产品。
综上所述,本发明的太阳能电池轻质组件用复合材料,通过甲基丙烯酸甲酯与复合引发剂按一定比例复配,通过不同引发温度的引发剂,使MMA逐步均匀交联,得到交联度更高,透光率高,韧性更强的材料。
以上述依据本发明的理想实施例为启示,通过上述的说明内容,相关工作人员完全可以在不偏离本项发明技术思想的范围内,进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容,必须要根据权利要求范围来确定其技术性范围。
Claims (9)
1.一种太阳能电池轻质组件用复合材料的制备方法,其特征在于,包括以下步骤:
步骤S1,将甲基丙烯酸甲酯与紫外吸收剂、光稳定剂预混,然后加入引发温度依次升高的第一引发剂、第二引发剂和第三引发剂搅拌均匀,并在引发温度各引发剂依次反应,真空脱泡后制得预混树脂;
步骤S2,将所述预混树脂涂布在耐候承载膜上,与纤维编织布复合,所述纤维编织布的另外一面复合离型膜,所述预混树脂充分浸润所述纤维编织布后制得太阳能电池轻质组件用复合材料。
2.如权利要求1所述的制备方法,其特征在于,
所述第一引发剂、第二引发剂和第三引发剂分别对应的引发温度分别是55℃~65℃、60℃~80℃和70℃~100℃。
3.如权利要求1所述的制备方法,其特征在于,
所述步骤S2中还包括将所述耐候承载膜进行电晕处理后涂布所述预混树脂,所述预混树脂充分浸润所述复合离型膜后制得增强高透前板。
4.如权利要求1所述的制备方法,其特征在于,
所述预混树脂中各组分的质量份数为:
甲基丙烯酸甲酯单体:80~98份;
紫外吸收剂:0.1~1份;
光稳定剂:0.1~2份;
含有偶氮二异庚腈ABVN的引发剂:2~3份;
含有偶氮二异丁腈AIBN的引发剂:1~2份;
含有过氧化苯甲酰BPO的引发剂:0.5~1份。
5.如权利要求4所述的制备方法,其特征在于,
所述光稳定剂为低聚物受阻胺光稳定剂。
6.一种如权利要求1方法制备得到的太阳能电池轻质组件用复合材料,其特征在于,包括:
耐候承载膜;
纤维编织布;其中,
所述纤维编织布充分浸润步骤S1所制备的预混树脂后交联固化。
7.如权利要求6所述的太阳能电池轻质组件用复合材料,其特征在于,
所述耐候承载膜的厚度为25~300μm;
所述纤维编织布的克重为40~600g/m2;
所述预混树脂浸润克重为50~800g/m2。
8.如权利要求6所述的太阳能电池轻质组件用复合材料,其特征在于,
所述耐候承载膜包括:ETFE、PVDF、PVF、耐候PET中的任意一种;
所述纤维编织布包括无机纤维编织布和有机纤维编织布中的任意一种或多种;其中,
所述有机纤维编织布包括涤纶、锦纶、腈纶、氨纶中的一种或多种;
所述无机纤维编织布包括玻璃纤维、石英玻璃纤维、陶瓷纤维、碳纤维中的一种或多种。
9.一种太阳能电池轻质组件,其特征在于,包括:
增强高透前板、封装胶膜、电池片、封装胶膜、增强背板;其
增强高透前板和/或增强背板采用如权利要求6所述的太阳能电池轻质组件用复合材料。
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