WO2019228049A1

WO2019228049A1 - High-efficiency protective composite board and preparation method therefor, and application and application method therefor

Info

Publication number: WO2019228049A1
Application number: PCT/CN2019/080318
Authority: WO
Inventors: 施正荣; 练成荣; 王伟力
Original assignee: 上迈（上海）新能源科技有限公司
Priority date: 2018-05-31
Filing date: 2019-03-29
Publication date: 2019-12-05

Abstract

Disclosed are a high-efficiency protective composite board and a preparation method therefor, an application and an application method therefor. Raw materials of the composite board comprise a fiber and a thermosetting powder coating; the weight ratio of the fiber to the thermosetting powder coating is 20-80 parts to 80-20 parts; the thermosetting powder coating is uniformly cross-linked and cured on the fiber; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating. In the present invention, in addition to the inherent advantages of the thermosetting powder coating, the composite board has excellent properties such as ultraviolet resistance, aging resistance, impact resistance, flexibility, fire resistance and the like; the composite board is stable in storage property, convenient to store and transport, and low in manufacturing costs; moreover, the composite board also realizes lightweight and flexibility and has attractive and light-transmitting decoration properties, and is suitable for serving as a photovoltaic packaging material, a building material, and a vehicle exterior decoration material.

Description

Efficient protective composite plate and preparation method, application and application method thereof

This application also requires that it be submitted to the Patent Office of the State Intellectual Property Office of China on May 31, 2018, with an application number of 201810552235.X, an invention name of "Highly Efficient Protective Composite Sheet and Its Preparation Method, Application and Application Method", and an Application Number of 201810552419.6 The priority of the Chinese patent application with the invention name of "Efficient protective composite sheet and its preparation method, application and application method" is incorporated herein by reference in its entirety.

Technical field

The invention belongs to the field of protective materials, and particularly relates to an efficient protective composite plate and a preparation method thereof. The invention also relates to an application and an application method of the efficient protective composite plate.

Background technique

Thermosetting powder coating refers to a solvent-free 100% solid powder coating. Thermosetting powder coatings are usually composed of thermosetting resins, curing agents, pigments, fillers and auxiliaries, because they are solvent-free, pollution-free, recyclable, environmentally friendly, save energy and resources, reduce labor intensity, and have high mechanical strength of the coating film. It is widely used as a protective film for substrates in the fields of construction, wood, automobiles and home appliances.

Because thermosetting powder coatings are powdery in nature, they have always been considered to be limited to coating protection materials for various types of metals or hard substrates such as wood or glass. The applicant's related prior application numbers of CN201610685536.0 and CN201610685240.9 respectively disclosed a packaging material for photovoltaic modules and a method for preparing the packaging material, and proposed to apply acrylic powder coating or super weather-resistant polyester powder The coating composite fiber cloth obtained a composite material as the packaging material for photovoltaic modules, replacing the traditional tempered glass layer or back sheet layer to solve the problems of light weight and convenient installation of photovoltaic packaging materials, and achieved surprising technical effects. This is Technology breakthroughs in the photovoltaic packaging industry.

With the continuous promotion and application of the applicant and a large number of experimental studies, it has been found that compounding different types of thermosetting powder coatings and fiber cloths under specific conditions can obtain composite materials with more excellent performance and technical effects. These composite materials can It is used in a wider range of fields to achieve weight reduction and flexibility of related products, and to give these products higher quality.

Summary of the Invention

In view of this, the object of the present invention is to provide an efficient protective composite plate, and a preparation method, application and application method thereof. On the premise of taking advantage of the inherent advantages of thermosetting powder coatings, it has very excellent anti-ultraviolet, anti-aging, impact resistance and Performance such as flexibility, fire resistance, etc., and stable storage performance, easy storage and transportation, and low manufacturing costs. At the same time, it is lightweight, flexible, and has beautiful, light-transmitting and decorative properties. It is very suitable for photovoltaic packaging materials, building materials, and automobiles. Exterior trim material.

It should be noted that the Chinese invention patents associated with the prior application numbers of CN201610685536.0 and CN201610685240.9 proposed that the acrylic powder coating or super weather-resistant polyester powder coating is thermally bonded to fiber cloth to obtain a composite material, and the composite material is used in photovoltaic At the same time, the cross-linking curing is completed during the lamination of the components. This is because those skilled in the art will consider this to be the best process path based on common knowledge and conventional experience, because the heating environment for lamination is also suitable for cross-linking and curing of powder coatings. Conditions, and the simultaneous implementation of the two can also facilitate the bonding of the composite thermosetting layer structure and other layer structures. Therefore, under this process path, even when encountering thermosetting materials, the thermoplastic materials commonly used in packaging materials are used for thermoplastics. In the case of technical problems such as different characteristics at the time of change, step-by-step heating and pressure cooling steps are used to try to solve these technical problems.

However, the applicant found in practical application that the composite material has poor storage stability due to the thermal bonding composite process and is not convenient for long-term transportation. Therefore, it is generally stipulated that long-distance transportation cannot be performed, and the nearby production package is generally not available. More than 3 months, this undoubtedly increases manufacturing costs; and acrylic powder coatings or ultra-weather-resistant polyester powder coatings usually generate bubbles and / or gases when cross-linked and cured. How many of these bubbles and gases are generated during the lamination of photovoltaic modules It will directly affect the flatness and lamination quality of photovoltaic laminated components. Therefore, the applicant hopes to conduct research experiments on the basis of these innovative composite materials, and finally get the technical solution of the present invention.

The technical scheme adopted by the present invention is as follows:

A high-efficiency protective composite board. The raw materials of the composite board are fiber and thermosetting powder coating, and the proportion by weight of the fiber and the thermosetting powder coating is 20-80 parts: 80-20 parts. Among them, the thermosetting property is: The powder coating is uniformly cross-linked and solidified on the fibers; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating.

A high-efficiency protective composite plate. The composite plate includes a thermoplastic film and a composite material layer that are composited into one body. The raw materials of the composite material layer are fiber and thermosetting powder coating. The fiber and the thermosetting powder coating are parts by weight. The proportion is 20-80 parts: 80-20 parts; wherein, the thermosetting powder coating is uniformly cross-linked and solidified on the fibers; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating.

More preferably, the proportion by weight of the fiber and the thermosetting powder coating is 30-70 parts: 70-30 parts; more preferably, the proportion by weight of the fiber and the thermosetting powder coating is 30- 50 parts: 70-50 parts.

Preferably, the fiber is a fiber cloth woven from a fiber material or a fiber cloth non-woven from a fiber material or chopped fibers or ground fibers. The present invention exemplifies the fiber shapes of the preferred solutions. These preferred fiber shapes are conducive to the preparation of highly effective protective composite boards and make their related performance more excellent. Of course, as a second preferred embodiment, the present invention can also use fibers of other shapes. As long as the appropriate preparation process is combined, the high-efficiency protective composite plate to be protected by the present invention can also be obtained.

Preferably, the basis weight of the fiber cloth ranges from 30 to 400 g / m ² .

Preferably, the fiber material is any one or a combination of glass fiber, carbon fiber and aramid fiber; preferably, the diameter of the monofilament of the fiber material is 3-23 μm.

Preferably, the acrylic powder coating includes an acrylic resin and a curing agent, wherein the refractive index range of the acrylic resin is 1.40-1.50, the epoxy equivalent range is 300-800g / eq or the hydroxyl value range is 15-70mgKOH / g or The acid value range is 15-85mgKOH / g, the glass transition temperature range is 40-70 ° C, the viscosity range is 75-600Pa · s, and the softening point temperature range is 100-120 ° C.

Preferably, the super weather-resistant polyester powder coating includes a super weather-resistant polyester resin and a curing agent, and the super weather-resistant polyester resin is one or both of a hydroxy super weather-resistant polyester resin or a carboxy super weather-resistant polyester resin. Wherein the hydroxyl value of the hydroxy super weather-resistant polyester resin ranges from 30 to 300 mgKOH / g, the glass transition temperature ranges from 50 to 75 ° C., and the viscosity ranges from 15 to 200 Pa · s; the carboxy super weather resistant polyester The resin has an acid value range of 15-85 mgKOH / g, a glass transition temperature range of 50-75 ° C, and a viscosity range of 15-200 Pa · s.

Preferably, the curing agent accounts for 5-25% by weight of the acrylic powder coating or the super weather-resistant polyester powder coating, and the curing agent is a blocked isocyanate, phthalic anhydride, trimellitic anhydride, sebacic acid, ten Any of mono-methylene diacid, dodecanedioic acid, tridecanedioic acid, tetradecanedioic acid, pendecanedioic acid, hexadecanedioic acid, carboxy polyester, hydrogenated epoxy, GMA acrylic acid Or a mixture of several arbitrary proportions.

Preferably, the thickness of the high-efficiency protective composite plate ranges from 0.2 to 15 mm.

Preferably, a method for preparing the high-efficiency protective composite plate as described above, said high-efficiency protective composite plate is prepared by using a fiber and a thermosetting powder coating pre-compositing process and then performing a hot pressing curing process, wherein the pre-compositing process uses Coating process or coating thermal bonding process or melt coextrusion process.

It should be noted that the present invention proposes that the pre-compositing process can adopt a coating process or a coating thermal bonding process or a melt coextrusion process. Further, the coating process refers to uniformly coating an acrylic powder coating or a super weather-resistant polyester powder coating. Coated on fiber cloth; coating thermal bonding process refers to uniformly coating acrylic powder coating or super weather-resistant polyester powder coating on fiber cloth and then heating to make acrylic powder coating or super weather-resistant polyester powder The coating adheres well to the fiber cloth, which is conducive to the implementation of the subsequent hot-press curing process. Specifically, the process proposed in CN201610685536.0 can be directly used; the melt coextrusion process refers to the combination of acrylic powder coating or super weather-resistant polyester powder coating with Chopped fibers or ground fibers are blended and extruded to obtain pre-composited fibers and thermosetting powder coatings in the shape of a sheet, which is conducive to the implementation of the subsequent hot-press curing process. Of course, as a second preferred embodiment, those skilled in the art will When implementing the present invention, it can also refer to other known preparation methods in the prior art, for example, referring to the preparation process of FRP in the prior art. Prepare the high-efficiency protective composite sheet of the present invention, which also belongs to the protection scope of the high-efficiency protective composite sheet of the present invention. On the basis of the core technical solution of the present invention, other existing thermosetting reinforced fiber products such as FRP are used to implement the present invention. Compared with the present invention, the technical solution should not be regarded as having novelty and creativity.

Preferably, the hot-press curing process steps include:

A10), placing the pre-compounded fiber and thermosetting powder coating in a hot pressing device;

A20), under a preset hot-pressing condition, hot-pressing the pre-composited fiber and the thermosetting powder coating, the acrylic powder coating or the super-weather-resistant polyester powder coating is crosslinked and cured on the fiber;

A30), obtaining the high-efficiency protective composite plate;

Preferably, the heating temperature range of the hot-pressing condition is 130-220 ° C, the heating time is 8-30 minutes, and the pressure range is 0.01-0.5Mpa; more preferably, the heating temperature range of the hot-pressing condition is 150- 200 ° C, heating time is 15-25 minutes, and the pressure range of the hot pressing conditions is 0.05-0.3Mpa.

Similarly, the above-mentioned hot-press curing process of the present invention is the preferred cross-linking curing process of the present invention. Of course, the present invention is not limited to using other cross-linking curing processes in other embodiments to prepare the highly effective protective composite to be protected by the present invention. Plate.

Preferably, the application of the highly efficient protective composite sheet as described above is applied to photovoltaic packaging materials, building materials, and automotive exterior materials; and to application fields that require these excellent performance materials.

Preferably, the photovoltaic module is applied to a photovoltaic packaging material to obtain a photovoltaic module, wherein the high-efficiency protective composite plate is used as a light-receiving surface encapsulation layer of the photovoltaic module; of course, as a sub-preferred solution, it may also be used as a backlight-surface encapsulation layer of the photovoltaic module.

Preferably, the photovoltaic module includes a photovoltaic module layer structure including a light-receiving surface encapsulating layer, a packaging film layer, a battery string, and a backlight encapsulating layer of the photovoltaic module, wherein the high-efficiency protective composite plate serves as a light-receiving surface encapsulating layer of the photovoltaic module. A backlight surface packaging layer made of a pre-composited fiber and a backlight surface packaging layer made of a thermosetting powder coating.

Preferably, an application method of the high-efficiency protective composite board as described above, wherein the photovoltaic module layer structure is prepared by a lamination process, and includes the following operation steps:

B10), laying the light-receiving surface packaging layer and the remaining material layers in order;

B20). Cover the high-temperature Teflon cloth on the top and enter the laminator to laminate to obtain the laminate.

B30). Edge cutting the laminate to obtain the photovoltaic module layer structure.

Preferably, an application method of the highly efficient protective composite board as described above, wherein the photovoltaic module layer structure is prepared by a lamination process, and the lamination process includes a first heating stage, a second heating stage, and a third In the pressure cooling stage, the heating temperature range of the first stage is 110-150 ° C and the heating time range is 100-600 seconds; the heating temperature range of the second stage is 130-200 ° C and the heating time range is 100-1200 seconds; The three-stage cooling temperature range is 25-60 ° C, and the applied pressure range is 0.05-0.25Mpa.

The present invention proposes to obtain a composite sheet by uniformly cross-linking and curing an acrylic powder coating or a super-weather-resistant polyester powder coating on fibers. After testing, it is found that the composite sheet obtained by the present invention has the inherent advantages of a thermosetting powder coating. It has very good anti-ultraviolet, anti-aging, impact resistance, flexibility, fire resistance and other properties, which is significantly better than the structural performance of the encapsulation layer obtained after cross-linking and curing when laminated directly on photovoltaic modules. This is CN201610685536.0 And CN201610685240.9 have technical effects not thought of, and the composite sheet of the present invention has stable storage performance, is convenient for storage and transportation, and has low manufacturing cost. At the same time, it also realizes light weight, flexibility, and has beautiful, light-transmitting and decorative properties, which is very suitable as Photovoltaic packaging materials, building materials, automotive exterior parts materials; especially suitable as light-receiving surface packaging layers for photovoltaic modules;

In order to further facilitate the lamination process when the composite sheet of the present invention is applied to a photovoltaic layered material as a layer structure, the present invention also proposes a composite sheet in which one side and a thermoplastic film are thermocompression-bonded into one body, which still retains The above technical effects, wherein the thermoplastic film can generally be seen as a certain layer structure of a photovoltaic module, such as a fluoroplastic film layer;

The present invention further specifically proposes a preferred photovoltaic module, a photovoltaic module layer structure with high-efficiency anti-cracking effect, and specifically includes a light-receiving surface packaging layer, a packaging film layer, a battery string, and a backlight surface packaging layer of the photovoltaic module. Among them, high-efficiency protection The composite board is used as the light-receiving surface encapsulation layer of photovoltaic modules, and the backlight surface encapsulation layer is made of pre-composited fibers and thermosetting powder coatings as raw materials. Such a photovoltaic layer structure can effectively ensure the adhesion of each layer structure during the lamination process. And more importantly, the applicant was surprised to find after a large number of tests and verifications that the photovoltaic module using this sequential laminated structure has high anti-cracking ability, which can obviously effectively prevent the battery string from crazing. No cracking occurs, that is, the curved surface / radian beautiful design is realized, and the packaging weight of the photovoltaic module is significantly reduced. Compared with the existing flexible crystalline silicon module, although the curved surface / radian beautiful design can be realized, the battery string is cracked. High rate, and the existing flexible thin-film modules not only have low photoelectric conversion efficiency, complicated manufacturing processes, but also This is high, and therefore, is preferably made of a photovoltaic module of the present invention facilitate the direct flexible bulk crystalline silicon component application.

On the basis of the above-mentioned preferred photovoltaic module technical solution, the present invention further proposes a preferred application process. As mentioned above, the present invention firstly prepares a highly effective protective composite plate through a hot-press curing process, so that the hot-press alone The composite sheet produced by the curing process is less likely to have defects, and if it is partially defective, it can be cut separately for other applications; then it can be used as the light-receiving surface encapsulation layer and / or backlight surface encapsulation layer of the photovoltaic module. The photovoltaic module layer structure is obtained by the lamination process, and the photovoltaic module layer structure is prepared by such a two-stage process, which effectively avoids defects in the raw materials of the light receiving surface packaging layer and / or the backlight surface packaging layer during curing during the lamination process. This leads to a problem that the defective rate of the entire laminated structure is high.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of the steps of the hot-press curing process according to Embodiments 1 and 9 of the present invention;

FIG. 2 is a block diagram of the lamination process steps of Embodiments 1 and 9 of the present invention; FIG.

FIG. 3 is a schematic diagram of a layer structure during a lamination process of Embodiments 1 and 9 of the present invention; FIG.

FIG. 4 is a schematic diagram of a laminated structure 100a of a photovoltaic module according to Embodiments 1 and 9 of the present invention; FIG.

5 is a schematic diagram of a laminated structure 100b of a photovoltaic module according to Embodiments 2 and 10 of the present invention;

FIG. 6 is a schematic diagram of a laminated structure 100c of a photovoltaic module according to Embodiments 3 and 11 of the present invention; FIG.

FIG. 7 is a schematic diagram of a laminated structure 100d of a photovoltaic module according to Example 4 and Example 12 of the present invention.

Detailed ways

This embodiment discloses a high-efficiency protective composite board. The raw materials of the composite board are fiber and thermosetting powder coating. The proportion by weight of the fiber and thermosetting powder coating is 20-80 parts: 80-20 parts. Among them, the thermosetting powder coating is uniform. It is crosslinked and solidified on the fiber; the thermosetting powder coating is acrylic powder coating or super weather-resistant polyester powder coating.

This embodiment also discloses a high-efficiency protective composite plate. The composite plate includes a thermoplastic film and a composite material layer which are combined into one body. The raw materials of the composite material layer are fiber and thermosetting powder coating, and the proportion by weight of the fiber and the thermosetting powder coating is It is 20-80 parts: 80-20 parts; wherein, the thermosetting powder coating is uniformly cross-linked and solidified on the fiber; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating.

The embodiment of the present invention proposes that an acrylic powder coating or a super-weather-resistant polyester powder coating is uniformly cross-linked and cured on a fiber to obtain a composite plate. After testing, it is found that the composite obtained by the present invention has the inherent advantages of a thermosetting powder coating. The board also has very good anti-ultraviolet, anti-aging, impact resistance, flexibility, fire resistance and other properties, which is significantly better than the structural performance of the encapsulation layer obtained after cross-linking and curing when laminated directly on photovoltaic modules. This is CN201610685536 .0 and CN201610685240.9 have technical effects not thought of, and the composite sheet of the present invention has stable storage performance, is convenient for storage and transportation, and has low manufacturing cost. At the same time, it also realizes light weight, flexibility, and has beautiful light-transmitting decorative properties. Suitable as photovoltaic packaging materials, building materials, automotive exterior parts materials; especially suitable as a light-receiving surface packaging layer for photovoltaic modules.

In order to more clearly explain the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely These are some of the embodiments described in the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without paying creative labor.

Example 1:

A high-efficiency protective composite plate 110a. The raw material of the composite plate 110a is a fiber cloth and a thermosetting powder coating woven from a fiber material, and the proportion by weight of the fiber cloth and the thermosetting powder coating is 20-80 parts: 80-20 parts; Among them, the thermosetting powder coating is uniformly cross-linked and cured on the fiber cloth to obtain a composite board; the thermosetting powder coating is an acrylic powder coating.

More preferably, the proportion by weight of fiber and acrylic powder coating is 30-70 parts: 70-30 parts; even more preferably, in this embodiment, the proportion by weight of fiber and acrylic powder coating is 30-50 Parts: 70-50 parts, which is more conducive to the comprehensive excellent performance of the high-efficiency protection composite board in the properties of anti-ultraviolet, anti-aging, impact resistance, flexibility, fire resistance, etc .;

In the actual implementation of the present invention, the recommended weight ratio of the fiber cloth and the thermosetting powder coating is 20-80 parts: 80-20 parts. Within this range, the composite sheet of the present invention having various excellent performances can be obtained, of course Ground, the technical effects close to the present invention are obtained by floating a range of parts by weight outside the upper and lower limit endpoints. Of course, these technical solutions that are suitable for floating to obtain similar technical effects should certainly be considered to be within the protection scope of the present invention.

Preferably, the weight per unit area of the fiber cloth ranges from 30 to 400 g / m ² ; the fiber material is any one or a combination of glass fiber, carbon fiber and aramid fiber; the monofilament diameter of the fiber material ranges from 3- 23 μm; specifically, in this embodiment, the fiber material is glass fiber.

In this embodiment, the acrylic powder coating includes an acrylic resin and a curing agent. Preferably, in the embodiment of the present invention, the refractive index range of the acrylic resin is 1.40-1.50, and the epoxy equivalent range is 300-800g / eq or the hydroxyl value range. 15-70mgKOH / g or acid value range 15-85mgKOH / g, glass transition temperature range 40-70 ° C, viscosity range 75-600Pa · s, softening point temperature range 100-120 ° C to ensure acrylic acid The resin has good insulation, weather resistance, and light transmittance. Further preferably, in the embodiment of the present invention, the acrylic resin is a hydroxy acrylic resin, a GMA (glycidyl methacrylate) acrylic resin, a carboxy acrylic resin, or a bifunctional group. Any one or several combinations of any proportion of acrylic resins. Specifically, in this embodiment, the acrylic resin is a GMA (glycidyl methacrylate) acrylic resin; preferably, the weight part of the curing agent accounts for acrylic acid. 5-25% by weight of powder coating, curing agent is blocked isocyanate, phthalic anhydride, trimellitic anhydride, sebacic acid, undecanedioic acid, dodecanedioic acid, ten Any one or several mixtures of any ratio among trioxane, tetradecanedioic acid, pentadecanoic acid, hexadecanedioic acid, carboxy polyester, hydrogenated epoxy, and GMA acrylic acid, specifically, In this embodiment, the curing agent is a blocked isocyanate, and the blocked isocyanate accounts for 10% by weight of the acrylic powder coating. Of course, those skilled in the art can select other types of curing agents and acrylic resins according to the type and actual situation of the acrylic resin. The curing agent in the range of 5-25% by weight (including the endpoints of 5% and 25%) can also achieve the same technical effect, and the embodiments of the present invention will not be described one by one;

Wherein, the acrylic powder coating is uniformly coated on the fiber cloth, and the acrylic powder coating is coated on the fiber cloth, and the weight per unit area ranges from 100 to 400 g / m ^2. Specifically, in this embodiment, the acrylic powder coating is coated The weight per unit area on the fiber cloth is 100g / m ² ;

The acrylic powder coating provided by the embodiment of the present invention may further add a certain weight part of an auxiliary agent, the weight part of the auxiliary agent accounts for 0-50% by weight of the acrylic powder coating material, and is used to further improve the transparency of the acrylic powder coating material, Weather resistance, insulation, and flame retardancy. At the same time, the color of the acrylic powder coating can be adjusted by adding additives according to the actual needs of the actual application, which is further beneficial to the needs of the actual application scene. Specifically, when the present invention is implemented, the additives are Polyamide wax, polyolefin wax, amide modified phenol urea surfactant, benzoin, polydimethylsiloxane, vinyltrichlorosilane, n-butyltriethoxysilane, methyl orthosilicate, Monoalkoxy pyrophosphates, acrylates, phenolic resins, urea resins, melamine formaldehyde resins, distearyl ethylene diamine, mixtures of ethylene oxide and propylene oxide, hindered phenols, thiodipropionic acid bis Ester, benzophenone, salicylate derivative, hindered amine, alumina, fumed silica, silica in any one or more of any proportion, of course, in the art The skilled person can select other types of auxiliaries according to the actual application needs, and the embodiments of the present invention will not be described in detail.

The acrylic powder coatings involved in the embodiments of the present invention can be prepared by using any of the known preparation techniques for powder coatings. Typical methods can be prepared after premixing, melt extrusion, milling, and other processes. Specifically, in In this embodiment, the acrylic resin and the curing agent are pre-mixed. Preferably, the pre-mixing time can be selected between 2-10 minutes (if the acrylic powder coating contains an auxiliary agent, it is also pre-mixed together), and then the pre-mixing is performed. The resulting mixture is extruded with a screw extruder and pressed into flakes. Preferably, the aspect ratio of the extruder can be selected between 15: 1-50: 1, and the heating temperature of the extruder is selected between 80-120 ° C. The rotation speed of the screw is selected between 200-800rpm. Finally, the flakes are crushed into small pieces and entered into a mill to be ground into a powder coating with a certain particle size. Preferably, the rotation speed of the mill is selected between 50-150rpm, preferably, acrylic powder. The particle size range of the finished coating is controlled between 35-300 μm. Of course, other process parameters or powder coating preparation processes can also be used to obtain the acrylic powder coating. It is believed that these are the conventional technical choices of those skilled in the art. Therefore, the preparation process of the acrylic powder coating will not be described in detail herein.

Specifically, in this embodiment, the high-efficiency protective composite plate 110a is prepared by using a fiber cloth and a thermosetting powder coating pre-compositing process and then performing a hot-pressing curing process. In this embodiment, the pre-compositing process uses a coating process. Specifically, the acrylic powder coating is evenly coated on the fiber cloth by a coating machine, and the coating device can also use a dusting head. At this time, the coating device implements the coating process in the form of dusting, and realizes the acrylic powder. The coating is evenly coated on the fiber cloth; other coating methods in the prior art can also be used; in other embodiments of the present invention, thermal bonding can also be performed after coating is completed, which is further beneficial to subsequent hot-press curing , But obviously, the process is also relatively tedious;

Preferably, the thickness of the high-efficiency protective composite plate 110a ranges from 0.2 to 15 mm; more preferably, in this embodiment, the thickness of the high-efficiency protective composite plate 110a ranges from 0.8 to 5 mm; the specific thickness can be selected according to application requirements;

Please refer to FIG. 1. In this embodiment, the hot-press curing process steps include:

A10): placing the pre-composited fiber cloth and the thermosetting powder coating (that is, the fiber cloth uniformly coated with the acrylic powder coating obtained in the above embodiment) in a hot pressing device;

A20). Under the preset hot-pressing conditions, hot-press the pre-composited fiber cloth and thermosetting powder coating, and the acrylic powder coating is crosslinked and cured on the fiber cloth;

The following hot-pressing conditions of the present invention are preferred technical solutions proposed by the applicant based on considerations such as energy consumption, cross-linking curing effect, and efficiency. Those skilled in the art can select the hot-pressing conditions according to actual needs during actual implementation. The heating temperature, heating time, and pressure are only required to ensure that the acrylic powder coating is crosslinked and cured on the fiber cloth, and the relevant changes in the hot pressing conditions during the implementation should not be regarded as limiting the scope of protection of the present invention.

Preferably, the heating temperature range of the hot-pressing condition is 130-220 ° C, and the heating time is 8-30 minutes; the pressure range of the hot-pressing condition is 0.01-0.5Mpa; specifically, in this embodiment, the The heating temperature range is 150-200 ° C, and the heating time is 15-25 minutes. The pressure range of the hot pressing condition is 0.05-0.3Mpa;

A30). An efficient protective composite plate 110a is obtained.

Further preferably, in this embodiment, before step A30), A21) and pressure cooling are also included. The preferred cooling temperature range suggested by the embodiment of the present invention is 25-60 ° C and the applied pressure range is 0.05-0.25Mpa. It is further beneficial to the flatness of the composite plate 110a and to maintain good flexibility.

The hot-pressing equipment in the embodiment of the present invention may directly select a laminating equipment, or other suitable hot-pressing equipment, or other hot-pressing conditions, as long as the acrylic powder coating is uniformly cross-linked and cured on the fiber cloth. ;

Preferably, the application of the high-efficiency protective composite board 110a as described in this embodiment is applied to photovoltaic packaging materials to obtain photovoltaic modules, where the high-efficiency protective composite board 110a is used as the light-receiving surface encapsulation layer of the photovoltaic module, as shown in FIG. 4 The photovoltaic module layer structure 100a includes the composite sheet layer 110a, the first EVA film layer 120a, the battery string 130a, the second EVA film layer 140a, and the back plate layer 150a as the light-receiving surface encapsulation layer in this embodiment 1. Specifically, please As shown in FIG. 2, in this embodiment, the photovoltaic module layer structure 100 a is prepared by a lamination process, and the lamination process includes the following operation steps:

B10). As shown in FIG. 3, the composite plate layer 110a, the first EVA film layer 120a, the battery string 130a, the second EVA film layer 140a, and the back plate layer 150a are sequentially laid;

B30). Cutting the edge of the laminate to obtain a photovoltaic module layer structure 100a.

The specific lamination process conditions can be selected from the existing lamination processes common to photovoltaic modules. Specifically, in this embodiment, the lamination process conditions are laminated at a temperature of 140-150 ° C for 15 minutes, and the specific lamination steps are known techniques. This embodiment is not specifically described.

Example 2:

The remaining technical solution of this embodiment 2 is the same as that of embodiment 1. The difference is that in this embodiment 2, a high-efficiency protective composite plate 110b, which includes a thermoplastic film and a composite material layer that are composited into one body under hot pressing conditions. The raw material of the composite material layer is a fiber cloth and a thermosetting powder coating woven from a fiber material. The proportion by weight of the fiber cloth and the thermosetting powder coating is 30-50 parts: 70-50 parts. Among them, the thermosetting powder coating is in the fiber. The composite material layer is obtained after uniform cross-linking and curing under hot pressing conditions on the cloth; the thermosetting powder coating is an acrylic powder coating; preferably, in this embodiment, the thermoplastic film is a fluoroplastic film;

The application of the high-efficiency protective composite board 110b in this embodiment as described above is applied to photovoltaic packaging materials to obtain photovoltaic modules. Among them, the high-efficiency protective composite board 110b is used as the light-receiving surface encapsulation layer of the photovoltaic module. See the photovoltaic module layer shown in FIG. 5 The structure 100b includes a composite plate layer 110b as a light-receiving surface packaging layer, a first EVA film layer 120b, a battery string 130b, a second EVA film layer 140b, and a back plate layer 150b according to the second embodiment.

Example 3:

The remaining technical solution of this embodiment 3 is the same as that of embodiment 2, except that in this embodiment, the high-efficiency protective composite plate 110c is prepared by a hot-press curing process. Please refer to FIG. 1 in combination. The hot-press curing process steps include:

A20). Under the pre-set hot-pressing conditions, hot-press the pre-composited fiber cloth and thermosetting powder coating, and the acrylic powder coating is cross-linked and cured on the fiber cloth; in this embodiment, the The heating temperature range is 170-190 ° C, and the heating time is 18-22 minutes. The pressure range of the hot pressing conditions is 0.1-0.2Mpa;

A21) a pressure cooling step, the cooling temperature range is 25-60 ° C, and the applied pressure range is 0.05-0.25Mpa;

A30), obtaining a composite plate 110c;

The application of the high-efficiency protective composite plate 110c in this embodiment 3 is applied to photovoltaic packaging materials to obtain photovoltaic modules. Among them, the high-efficiency protective composite plate 110c is used as the light-receiving surface encapsulation layer of the photovoltaic module. 100c, which includes the composite sheet layer 110c, the EVA film layer 120c, and the battery string 130c as the light-receiving surface encapsulation layer of this embodiment 3, which uses the pre-composited fiber and thermosetting powder coating disclosed in CN201610685536.0 Embodiment 1 A backlight surface encapsulation layer 140c made by applying a thermal bonding process) (the backlight surface encapsulation layer 140c is crosslinked and cured during lamination), and a back plate 150c;

Since the backlight surface encapsulation layer 140c needs to be cross-linked and cured during the lamination process, preferably, this embodiment can adopt the lamination process proposed by CN201610927383.6; the details are as follows:

The photovoltaic module layer structure 100c of this embodiment 3 is prepared by a lamination process. Please refer to FIG. 2 in combination, including the following operation steps:

B10), laying the composite plate layer 110c, the EVA film layer 120c, the battery string 130c, the backlight surface packaging layer 140c and the back plate 150c in order;

B30). Cutting the edge of the laminate to obtain a photovoltaic module layer structure 100c.

Preferably, in this embodiment, the lamination process includes a first heating stage, a second heating stage, and a third pressure cooling stage. The heating temperature range of the first stage is 110-150 ° C, and the heating time range is 100-600. Seconds; the heating temperature range of the second stage is 130-200 ° C, and the heating time range is 100-1200 seconds; the cooling temperature range of the third stage is 25-60 ° C, and the applied pressure range is 0.05-0.25Mpa; its working principle can be Directly refer to the relevant description content of CN201610927383.6, and the embodiment of the present invention does not specifically describe it.

Example 4:

In this embodiment 4, the first high-efficiency protective composite plate 110d of the same embodiment 2 and the second high-efficiency protective composite plate 150d of the same embodiment 1 are included;

In the application of the high-efficiency protective composite sheet of this embodiment 4, it is applied to photovoltaic packaging materials to obtain photovoltaic modules. Among them, the first high-efficiency protective composite sheet 110d and the second high-efficiency protective composite sheet layer 150d are used as the light-receiving surface packaging layer and For the back packaging layer, please refer to the photovoltaic module layer structure 100d shown in FIG. 7, which includes the first high-efficiency protective composite sheet layer 110d, the first EVA film layer 120d, the battery string 130d, and the first Two EVA film layers 140d, and a second high-efficiency protective composite sheet layer 150d as a back surface encapsulation layer in this embodiment 4.

It should be noted that regarding the specific parameters and type selection of the acrylic powder coating and fiber cloth in the specific embodiment of the present invention, those skilled in the art can directly adopt the technical information disclosed by CN201610685536.0, and the embodiments of the present invention are not one by one Expand example description.

It should also be noted that, in other embodiments of the present invention, the material of the encapsulating film layer may be the ethylene-vinyl acetate copolymer (English abbreviated as EVA) described in Examples 1-4 and Examples 7-8, It can also be polyolefin elastomer (POE for short) or polyvinyl butyral (PVB for short) or polyethylene terephthalate film (PET for short). Of course, it can also be The packaging film materials of other known packaging materials for photovoltaic modules are not specifically limited in the present invention.

Example 5:

The remaining technical solutions of this embodiment 5 are the same as those of embodiment 1 or embodiment 2, except that in this embodiment 5, the application of the high-efficiency protection

composite plate

110a or 110b is applied to the building materials to obtain the building transparent curtain wall and / or other Building material structure.

Example 6:

The remaining technical solutions of this embodiment 6 are the same as those of embodiment 1 or embodiment 2, except that in this embodiment 6, the application of the high-efficiency protective

composite plate

110a or 110b is applied to the automobile exterior trim material to obtain the automobile exterior trim.

Example 7:

The remaining technical solutions of this embodiment 7 are the same as those of embodiment 1 or embodiment 2, except that the fibers of this embodiment are fibrous cloths made of a fibrous material.

Example 8:

The remaining technical solutions of this embodiment 8 are the same as those of embodiment 1 or embodiment 2, except that the fibers of this embodiment 8 are chopped fibers with a length in the range of 3-50 mm or granular ground fibers, and this embodiment The pre-compositing process uses a melt coextrusion process; specifically, in this embodiment, the fibers use chopped fibers of 3mm; the melt coextrusion process specifically: blends acrylic powder coating with 3mm chopped fibers and passes A twin-screw extruder is used to obtain a pre-composite fiber and thermosetting powder coating in the shape of a sheet. The heating temperature range during melt coextrusion can be selected between 110-120 ° C, depending on the actual extrusion needs, as long as it is ensured It is sufficient that the acrylic powder coating is in a molten state but does not reach the curing temperature. It is believed that these are all conventional technical choices by those skilled in the art, and specific descriptions will not be given one by one.

Through testing, the relevant excellent characteristics of the composite boards prepared in Examples 1-4 and 7-8 are simultaneously shown in:

1. Performance of raw materials: no solvent, no pollution, recyclable, environmental protection, saving energy and resources, reducing labor intensity;

2. Storage performance: can be stored for a long time;

3. Weather resistance performance: Pass QUVB resistance 1500 hours test, pass Xenon lamp 3000 hours test;

4. Mechanical performance: the hardness of the pencil is above 2H; the tensile strength reaches about 46Mpa, which is basically the same as the tensile strength of glass; the elongation at break ranges from 150-250%;

5. Flexible performance: it will not deform or break after bending at any angle, and it can be applied to the installation of complex curved surfaces;

6. Transparent decorative performance: The transmittance reaches above 90%, which basically achieves the transparent decorative effect of glass;

7, lightweight performance: the weight per unit area is equal to or less than 1kg / m ² , which is far less than the unit weight of glass;

8. Cost performance: material cost is far lower than fluororesin materials and silicone materials;

Example 7 is inferior to Examples 1-4 in terms of mechanical performance, and Example 8 is inferior to Examples 1-4 in terms of preparation process, flexibility, and mechanical performance; therefore, Examples 1-4 are more advantageous as the present invention. Preferred implementation technical solutions;

The composite sheet prepared by the present invention has excellent characteristics and low manufacturing cost. It is a technical effect that CN201610685536.0 and CN201610685240.9 did not expect. Since the composite sheet of the embodiment of the present invention has the above excellent performance, it is not only very suitable as Photovoltaic packaging materials can also be directly used as building materials and automotive exterior materials, as shown in Examples 5 and 6, and application areas that require these excellent performance materials. These applications in other areas of the composite sheet of the invention also belong to the same. The protection scope of the present invention.

It also needs special explanation. The applicant of the present invention is also particularly surprised to find that the laminated structure of the composite plate layer 110c, the EVA film layer 120c, the battery string 130c, and the backlight surface encapsulation layer 140c in the embodiment 3 of the present invention can effectively avoid the battery string 130c. Occurrence of cracks, which will not occur in curved installation environments, that is, the curved surface / radian aesthetic design is realized, and the packaging weight of photovoltaic modules is significantly reduced. Although the existing flexible crystalline silicon modules can achieve curved surface / radian aesthetics Design, but the string string cracking rate is very high, and the existing flexible thin-film modules not only have low photoelectric conversion efficiency, complicated manufacturing processes, but also high manufacturing costs; therefore, the preferred photovoltaic module proposed in this embodiment 3 is directly beneficial to flexible crystal modules. Mass promotion and application of silicon components.

Through a large number of application cases of the applicant, it is shown that the pass rate of the battery string cracking in Example 3 of the present invention reaches more than 99% (that is, no cracking occurs), and the cracking passing rate is obviously better than that of Examples 1 and 2. The qualified rate of hidden cracks in Example 4 meets the standard requirements of the photovoltaic industry for hidden cracks. The photovoltaic module proposed in Example 3 belongs to the most preferred embodiment of the present invention which is applied to photovoltaic packaging materials to obtain photovoltaic modules.

It should be emphasized that, in other embodiments of the present invention, the thermosetting powder coating in the backlight surface encapsulation layer 140c of Example 3 may also be adopted. Fiber cloth may also be used to compound other types of thermosetting powder coatings, such as polyester powder coatings. , Epoxy powder coatings, polyurethane powder coatings, epoxy mixed powder coatings, fluorocarbon powder coatings and other thermosetting powder coatings. The applicant has verified through testing that the type of thermosetting powder coating and fiber cloth are used as packaging materials (composite The methods can all adopt the preparation method of the packaging material disclosed in CN201610685536.0) applied in Example 3 of the present invention as its backlight surface encapsulation layer 140c. The backlight surface encapsulation layer 140c is crosslinked and cured during the lamination process, and can be obtained with The effect of the anti-cracking technology of the third embodiment is the same or not much different; therefore, the invention does not specifically limit the specific type of the thermosetting powder coating in the backlight surface packaging layer.

The present invention further proposes a preferred application process for photovoltaic encapsulation materials. As mentioned above, in Examples 1-4 and 7-8 of the present invention, a high-efficiency protective composite sheet is first prepared through a hot press curing process. The composite sheet produced by the hot-press curing process is less likely to have defects, and if it is partially defective, it can be cut separately and used for other applications, reducing the rate of defective products and saving costs; then it is used as a photovoltaic module The light-receiving surface encapsulation layer and / or backlight surface encapsulation layer are prepared by a lamination process to obtain a photovoltaic module layer structure. The photovoltaic module layer structure is prepared by such a two-stage process, which effectively avoids the light-receiving surface encapsulation layer and / or the backlight surface encapsulation. The problem that the raw material of the layer is cured during the lamination process causes high defects in the entire laminated structure due to defects.

Example 9:

A high-efficiency protective composite plate 110a. The raw material of the composite plate 110a is a fiber cloth and a thermosetting powder coating woven from a fiber material, and the proportion by weight of the fiber cloth and the thermosetting powder coating is 20-80 parts: 80-20 parts; Among them, the thermosetting powder coating is uniformly cross-linked and solidified on the fiber cloth to obtain a composite board; the thermosetting powder coating is a super weather-resistant polyester powder coating.

More preferably, the proportion by weight of the fiber and the ultra-weather-resistant polyester powder coating is 30-70 parts: 70-30 parts; even more preferably, in this embodiment, the proportion by weight of the fiber and the ultra-weather-resistant polyester powder coating is The proportion is 30-50 parts: 70-50 parts, which is more conducive to the comprehensive and excellent performance of the high-efficiency protective composite sheet in terms of anti-ultraviolet, anti-aging, impact resistance, flexibility, and fire resistance;

In this embodiment, the super weather-resistant polyester powder coating includes a super weather-resistant polyester resin and a curing agent; preferably, in the embodiment of the present invention, the super weather-resistant polyester resin is a hydroxy super weather-resistant polyester resin or a carboxyl super weather-resistant polymer A mixture of one or two of the ester resins is used to ensure that the super weather-resistant polyester resin has good insulation and weather resistance, and meets the requirements of relevant standards. Specifically, in this embodiment, the super weather-resistant polyester resin is a hydroxy Weather-resistant polyester resin;

Preferably, in the embodiment of the present invention, the hydroxy super weather-resistant polyester resin is a mixture obtained by polymerizing one or more monomers of neopentyl glycol, adipic acid, and ethylene glycol. Of course, in the art, The technician can select other types of monomers to polymerize to obtain a hydroxy super weather-resistant polyester resin according to actual needs. The examples of the present invention are not exemplified one by one. Specifically, in this embodiment, the super weather-resistant polyester resin is made of adipic acid. Monomer polymerization

Preferably, in the examples of the present invention, the hydroxyl value of the hydroxy super weather-resistant polyester resin ranges from 30 to 300 mgKOH / g, the glass transition temperature ranges from 50 to 75 ° C., and the viscosity ranges from 15 to 200 Pa · s. Specifically, In this embodiment, the hydroxyl value of the hydroxy super-weatherable polyester resin is 100 mgKOH / g, the glass transition temperature range is 60 ° C., and the viscosity range is 80 Pa · s;

In other embodiments of the present invention, the super weather-resistant polyester resin may also be a carboxyl super weather-resistant polyester resin, a mixture obtained by polymerizing one or two monomers of terephthalic acid and isophthalic acid. Weathering polyester resin has an acid value range of 15-85mgKOH / g, a glass transition temperature range of 50-75 ° C, and a viscosity range of 15-200Pa · s;

Preferably, in the embodiment of the present invention, the weight part of the curing agent accounts for 2-20% of the weight of the super weather-resistant polyester powder coating, and the curing agent is triglycidyl isocyanurate, triglycidyl trimellitate, Any one or more of any ratio of diglycidyl terephthalate, glycidyl methacrylate, hydroxyalkylamide, and isocyanate. Specifically, in this embodiment, the curing agent is isocyanate. Uric acid triglycidyl ester, isocyanuric acid triglycidyl ester accounts for 5% by weight of the hydroxy super weathering polyester powder coating. Of course, those skilled in the art can choose according to the type and actual situation of the super weathering polyester resin. Other types of curing agents and curing agents in the range of 2-20% by weight (including the endpoints of 2% and 20%) can also achieve the same technical effect, and the embodiments of the present invention will not be described one by one;

Among them, the super weather-resistant polyester powder coating is evenly coated on the fiber cloth, and the super weather-resistant polyester powder coating is coated on the fiber cloth, and the unit weight range is 100-400 g / m ^2. Specifically, in this embodiment, The weight per unit area of the super weather-resistant polyester powder coating applied on the fiber cloth is 100g / m ² ;

Of course, in other specific implementation manners, the super weather-resistant polyester powder coating provided in the embodiment of the present invention may further add a certain weight part of an auxiliary agent, and preferably, the auxiliary weight part accounts for the super weather-resistant polyester powder coating material. 0-40% by weight, used to further improve the insulation and weather resistance of the super weather-resistant polyester powder coating. At the same time, according to actual needs, the color of the super weather-resistant polyester powder coating can be adjusted by adding additives to further facilitate actual installation. Application, specifically, in the practice of the present invention, the auxiliary agent is polyamide wax, polyolefin wax, amide-modified phenol urea surfactant, benzoin, polydimethylsiloxane, vinyltrichlorosilane, n- Butyltriethoxysilane, methyl orthosilicate, monoalkoxy pyrophosphate, acrylates, phenolic resins, urea resins, melamine formaldehyde resins, distearyl ethylene diamine, ethylene oxide and cyclic Mixture of oxypropane, hindered phenol, thiodipropionate diester, benzophenone, salicylate derivative, hindered amine, alumina, fumed silica, tetrabromobisphenol A, decabromodiphenylethane Trimethyl phosphate , Aluminum hydroxide, magnesium hydroxide, barium sulfate, titanium dioxide, carbon black, any combination of any ratio, of course, those skilled in the art can choose other types of additives according to actual needs, The embodiments of the present invention are not described in detail.

The ultra-weather-resistant polyester powder coatings involved in the embodiments of the present invention can be prepared by using any of the known preparation techniques for powder coatings. A typical method can be prepared after premixing, melt extrusion, milling, and other processes. In this embodiment, the super-weatherable polyester resin is pre-mixed with the curing agent. Preferably, the pre-mixing time can be selected between 2-10 minutes (if the super-weather-resistant polyester powder coating contains an auxiliary agent, also Pre-mixing), and then extruding the pre-mixed mixture into a sheet with a screw extruder, preferably, the aspect ratio of the extruder can be selected between 15: 1-50: 1, the extruder The heating temperature is selected between 80-120 ° C, and the screw speed is selected between 200-800rpm. Finally, the flakes are pulverized into small pieces and entered into a mill to be ground into a powder coating with a certain particle size. Preferably, the speed of the mill is selected at 50-150 rpm, preferably, the particle size range of the finished product of the super weather-resistant polyester powder coating is controlled between 35-300 μm. Of course, other process parameters or powder coating preparation processes can also be used to prepare super weather-resistant polyester powder coatings. It is believed that these are the conventional technical choices of those skilled in the art. Therefore, the preparation process of super weather-resistant polyester powder coatings is not described in this article. Expand the description in detail.

Specifically, in this embodiment, the high-efficiency protective composite plate 110a is prepared by using a fiber cloth and a thermosetting powder coating pre-compositing process and then performing a hot-pressing curing process. In this embodiment, the pre-compositing process uses a coating process. Specifically, the super weather-resistant polyester powder coating is evenly coated on the fiber cloth by a coating machine, and the coating device can also use a dusting head. At this time, the coating device implements the coating process in the form of dusting. The super weather-resistant polyester powder coating is uniformly coated on the fiber cloth; other coating methods in the prior art may also be adopted; in other embodiments of the present invention, thermal bonding may be performed after the coating is completed, and further Conducive to subsequent hot-press curing, but obviously, the process is also relatively cumbersome;

A10) Place the pre-composited fiber cloth and the thermosetting powder coating (that is, the fiber cloth uniformly coated with the super weather-resistant polyester powder coating obtained in the above embodiment) in a hot pressing device;

A20). Under the pre-set hot-pressing conditions, pre-compound fiber cloth and thermosetting powder coating are hot-pressed, and the super-weather-resistant polyester powder coating is crosslinked and cured on the fiber cloth;

The following hot-pressing conditions of the present invention are preferred technical solutions proposed by the applicant based on considerations such as energy consumption, cross-linking curing effect, and efficiency. Those skilled in the art can select the hot-pressing conditions according to actual needs during actual implementation. The heating temperature, heating time and pressure only need to ensure that the super-weather-resistant polyester powder coating is crosslinked and cured on the fiber cloth, and the relevant changes in the hot pressing conditions during the implementation should not be regarded as limiting the scope of the present invention.

A30). An efficient protective composite plate 110a is obtained.

The hot-pressing equipment in the embodiment of the present invention may directly select a laminating equipment, or other suitable hot-pressing equipment, or other hot-pressing conditions, as long as the super-weather-resistant polyester powder coating is ensured to be uniformly cross-linked and cured on the fiber cloth. On it

Preferably, the application of the high-efficiency protective composite board 110a as described in this embodiment is applied to photovoltaic packaging materials to obtain photovoltaic modules, where the high-efficiency protective composite board 110a is used as the light-receiving surface encapsulation layer of the photovoltaic module, as shown in FIG. 4 The photovoltaic module layer structure 100a includes the composite sheet layer 110a, the first EVA film layer 120a, the battery string 130a, the second EVA film layer 140a, and the back plate layer 150a as the light-receiving surface encapsulation layer of this embodiment 9. Specifically, please As shown in FIG. 2, in this embodiment, the photovoltaic module layer structure 100 a is prepared by a lamination process, and the lamination process includes the following operation steps:

Example 10:

The remaining technical solution of this embodiment 10 is the same as that of embodiment 9, except that in this embodiment 10, a high-efficiency protective composite plate 110b, the composite plate 110b includes a thermoplastic film and a composite material layer that are composited into one body under hot pressing conditions. The raw material of the composite material layer is a fiber cloth and a thermosetting powder coating woven from a fiber material. The proportion by weight of the fiber cloth and the thermosetting powder coating is 30-50 parts: 70-50 parts. Among them, the thermosetting powder coating is in the fiber. The composite material layer is obtained after uniform cross-linking and curing under hot pressing conditions on the cloth; the thermosetting powder coating is a super weather-resistant polyester powder coating; preferably, in this embodiment, the thermoplastic film is a fluoroplastic film;

The application of the high-efficiency protective composite board 110b in this embodiment as described above is applied to photovoltaic packaging materials to obtain photovoltaic modules. Among them, the high-efficiency protective composite board 110b is used as the light-receiving surface encapsulation layer of the photovoltaic module. See the photovoltaic module layer shown in FIG. 5 The structure 100b includes a composite plate layer 110b as a light-receiving surface encapsulation layer, a first EVA film layer 120b, a battery string 130b, a second EVA film layer 140b, and a back plate layer 150b according to the tenth embodiment.

Example 11:

The remaining technical solution of this embodiment 11 is the same as that of embodiment 10, except that in this embodiment, the high-efficiency protective composite plate 110c is prepared by a hot press curing process. Please refer to FIG. 1 in combination. The hot press curing process steps include:

A20). Under the pre-set hot-pressing conditions, pre-compound fiber cloth and thermosetting powder coating are hot-pressed, and the super-weather-resistant polyester powder coating is cross-linked and cured on the fiber cloth. In this embodiment, heat The heating temperature range of the pressing conditions is 170-190 ° C, and the heating time is 18-22 minutes; the pressure range of the heating conditions is 0.1-0.2Mpa;

A30), obtaining a composite plate 110c;

The application of the high-efficiency protective composite plate 110c in this embodiment 11 is applied to photovoltaic packaging materials to obtain photovoltaic modules. Among them, the high-efficiency protective composite plate 110c is used as the light-receiving surface encapsulation layer of the photovoltaic module. Please refer to the photovoltaic module layer structure shown in FIG. 6 100c, which includes the composite sheet layer 110c, the EVA film layer 120c, and the battery string 130c as the light-receiving surface encapsulation layer of this embodiment 11, which uses the pre-composited fiber and thermosetting powder coating disclosed in CN201610685240.9 Embodiment 9 (that is, adopts A backlight surface encapsulation layer 140c made by applying a thermal bonding process) (the backlight surface encapsulation layer 140c is crosslinked and cured during lamination), and a back plate 150c;

The photovoltaic module layer structure 100c of this embodiment 11 is prepared by a lamination process. Please refer to FIG. 2 in combination, including the following operation steps:

Example 12:

In the twelfth embodiment, the first high-efficiency protective composite plate 110d of the same embodiment 10 and the second high-efficiency protective composite plate 150d of the embodiment 9 are included;

In the application of the high-efficiency protective composite sheet of this Example 12, it is applied to photovoltaic packaging materials to obtain photovoltaic modules, wherein the first high-efficiency protective composite sheet 110d and the second high-efficiency protective composite sheet layer 150d are used as the light-receiving surface packaging layer of the photovoltaic module and For the backlight surface encapsulation layer, please refer to the photovoltaic module layer structure 100d shown in FIG. 7, which includes the first high-efficiency protective composite sheet layer 110d, the first EVA film layer 120d, the battery string 130d, The second EVA film layer 140d and the second high-efficiency protective composite sheet layer 150d as the backlight surface encapsulation layer in this embodiment 4.

It should be noted that, regarding the specific parameters and type selection of the super weather-resistant polyester powder coating and fiber cloth in the specific embodiment of the present invention, those skilled in the art can directly adopt the technical information disclosed by CN201610685240.9, an embodiment of the present invention Not one by one.

It should also be noted that, in other embodiments of the present invention, the material of the encapsulating film layer may be the ethylene-vinyl acetate copolymer (English abbreviated as EVA) described in Examples 9-12 and 15-16, It can also be polyolefin elastomer (POE for short) or polyvinyl butyral (PVB for short) or polyethylene terephthalate film (PET for short). Of course, it can also be The packaging film materials of other known packaging materials for photovoltaic modules are not specifically limited in the present invention.

Example 13:

The remaining technical solutions of this embodiment 13 are the same as those of embodiment 9 or embodiment 10. The difference is that in this embodiment 13, the application of high-efficiency protection

composite board

110a or 110b is applied to building materials to obtain building transparent curtain walls and / or other Building material structure.

Example 14:

The remaining technical solutions of this embodiment 14 are the same as those of embodiment 9 or embodiment 10, except that in this embodiment 14, the application of the high-efficiency protective

composite plate

Example 15:

The remaining technical solutions of the fifteenth embodiment are the same as those of the ninth embodiment or the tenth embodiment, except that the fibers in this embodiment are fibrous cloths made of a fibrous material.

Embodiment 16:

The remaining technical solutions of this embodiment 16 are the same as those of embodiment 9 or embodiment 10, except that the fibers of this embodiment 16 are chopped fibers with a length ranging from 3 to 50 mm or granular ground fibers, and this embodiment The pre-compositing process uses a melt coextrusion process; specifically, in this embodiment, the fibers are chopped fibers of 3 mm; the melt coextrusion process is specifically: co-extruded super weather-resistant polyester powder coating with 3 mm chopped fibers After mixing, it is extruded through a twin-screw extruder to obtain a pre-composite fiber and thermosetting powder coating in the shape of a sheet. The heating temperature range during melt coextrusion can be selected between 110-120 ° C, depending on the actual extrusion needs. As long as it is ensured that the super-weather-resistant polyester powder coating is in a molten state but does not reach the curing temperature, it is believed that these are the conventional technical choices of those skilled in the art, and specific descriptions will not be developed one by one.

Through testing, the relevant excellent characteristics of the composite boards prepared in Examples 9-12 and 15-16 are simultaneously shown in:

2. Storage performance: can be stored for a long time;

Example 15 is inferior to Examples 9-12 in terms of mechanical performance, and Example 16 is inferior to Examples 9-12 in terms of preparation process, flexibility, and mechanical performance; therefore, Examples 9-12 are more advantageous as the present invention Preferred implementation technical solutions;

The composite sheet prepared by the present invention has excellent characteristics and low manufacturing cost. It is a technical effect that CN201610685536.0 and CN201610685240.9 did not expect. Since the composite sheet of the embodiment of the present invention has the above excellent performance, it is not only very suitable as Photovoltaic packaging materials can also be directly used as building materials and automotive exterior parts materials as shown in Examples 13 and 14, as well as application areas that require these excellent performance materials. These other areas of application of the composite sheet of the invention also belong to The protection scope of the present invention.

It also needs special explanation. The applicant of the present invention also found that the laminated structure of the composite sheet layer 110c, the EVA film layer 120c, the battery string 130c, and the backlight encapsulation layer 140c in the embodiment 11 of the present invention is particularly surprising. Occurrence of cracks, which will not occur in curved installation environments, that is, the curved surface / radian aesthetic design is realized, and the packaging weight of photovoltaic modules is significantly reduced. Although the existing flexible crystalline silicon modules can achieve curved surface / radian aesthetics Design, but the string string cracking rate is very high, and the existing flexible thin-film modules not only have low photoelectric conversion efficiency, complicated manufacturing processes, but also high manufacturing costs; therefore, the preferred photovoltaic module proposed in this embodiment 11 is directly beneficial to flexible crystal modules. Mass promotion and application of silicon components.

Through a large number of application cases of the applicant, it is shown that the pass rate of the battery string cracking in Example 11 of the present invention is more than 99% (that is, no cracking occurs), and the cracking passing rate is obviously better than that of Examples 9 and 10. The hidden crack pass rate of Example 12 meets the standard requirements of the photovoltaic industry for hidden cracks. The photovoltaic module proposed in this Example 11 belongs to the most preferred embodiment of the present invention applied to photovoltaic packaging materials to obtain a photovoltaic module.

It should be emphasized that, in other embodiments of the present invention, the thermosetting powder coating in the backlight surface encapsulation layer 140c of Example 11 may also be used. Fiber cloth may also be used to compound other types of thermosetting powder coatings, such as acrylic powder coatings, Thermosetting powder coatings such as epoxy powder coatings, polyurethane powder coatings, epoxy hybrid powder coatings, and fluorocarbon powder coatings. The applicant has verified through tests that the type of thermosetting powder coating is used as a packaging material after compounding with fiber cloth (composite method) The packaging method disclosed in CN201610685240.9 can be used) as the backlight surface encapsulation layer 140c in Example 11 of the present invention. The backlight surface encapsulation layer 140c is crosslinked and cured during the lamination process. Embodiment 11 has the same or similar effect of anti-cracking technology; therefore, the present invention does not specifically limit the specific type of the thermosetting powder coating in the backlight surface packaging layer.

The present invention further proposes a preferred application process for photovoltaic encapsulation materials. As mentioned above, in Examples 9-12 and 15-16 of the present invention, a high-efficiency protective composite sheet is first prepared by a hot-press curing process. The composite sheet produced by the hot-press curing process is less likely to have defects, and if it is partially defective, it can be cut separately and used for other applications, reducing the rate of defective products and saving costs; then it is used as a photovoltaic module The light-receiving surface encapsulation layer and / or backlight surface encapsulation layer are prepared by a lamination process to obtain a photovoltaic module layer structure. The photovoltaic module layer structure is prepared by such a two-stage process, which effectively avoids the light-receiving surface encapsulation layer and / or the backlight surface encapsulation. The problem that the raw material of the layer is cured during the lamination process causes high defects in the entire laminated structure due to defects.

It will be apparent to those skilled in the art that the present invention is not limited to the details of the above-mentioned exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, the embodiments are to be regarded as exemplary and non-limiting in every respect, and the scope of the present invention is defined by the appended claims rather than the above description, and therefore is intended to fall within the claims. All changes that are within the meaning and scope of equivalent elements are encompassed by the invention. Any reference signs in the claims should not be construed as limiting the claims involved.

In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment includes only an independent technical solution. This description of the specification is for clarity only, and those skilled in the art should take the specification as a whole. The technical solutions in the embodiments can also be appropriately combined to form other implementations that can be understood by those skilled in the art.

Claims

An efficient protective composite plate, characterized in that the raw materials of the composite plate are fiber and thermosetting powder coating, and the proportion by weight of the fiber and the thermosetting powder coating is 20-80 parts: 80-20 parts;

Wherein, the thermosetting powder coating is uniformly cross-linked and solidified on the fiber; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating.
A high-efficiency protective composite plate, characterized in that the composite plate includes a thermoplastic film and a composite material layer that are integrated into one body, and the raw materials of the composite material layer are fiber and thermosetting powder coating, and the fiber and the thermosetting powder The proportion by weight of the coating is 20-80 parts: 80-20 parts;

Wherein, the thermosetting powder coating is uniformly cross-linked and solidified on the fiber; the thermosetting powder coating is an acrylic powder coating or a super weather-resistant polyester powder coating.
The high-efficiency protective composite board according to claim 1 or 2, wherein the fibers are a fiber cloth woven from a fiber material or a fiber cloth non-woven from a fiber material or chopped fibers or ground fibers .
Efficient protection composite sheet of claim 1 or claim 2, wherein the fiber basis weight in the range of 30-400g / m 2.
The high-efficiency protective composite board according to claim 1 or 2, wherein the acrylic powder coating comprises an acrylic resin and a curing agent, wherein the refractive index range of the acrylic resin is 1.40-1.50 and the epoxy equivalent range is 300. -800g / eq or hydroxyl value range 15-70mgKOH / g or acid value range 15-85mgKOH / g, glass transition temperature range 40-70 ° C, viscosity range 75-600Pa · s, softening point temperature range 100 -120 ° C.
The high-efficiency protective composite sheet according to claim 1 or 2, wherein the ultra-weather-resistant polyester powder coating comprises a super-weather-resistant polyester resin and a curing agent, and the super-weather-resistant polyester resin is a hydroxy-super weather-resistant polyester Resin or a mixture of one or two of carboxyl super weather-resistant polyester resins; wherein the hydroxyl value of the hydroxy super weather-resistant polyester resin ranges from 30-300 mgKOH / g, the glass transition temperature ranges from 50-75 ° C, and the viscosity The range is 15-200Pa · s; the acid value range of the carboxyl super weather-resistant polyester resin is 15-85mgKOH / g, the glass transition temperature range is 50-75 ° C, and the viscosity range is 15-200Pa · s.
A method for preparing an efficient protective composite sheet according to any one of claims 1-6, wherein the efficient protective composite sheet is prepared by using a fiber and a thermosetting powder coating pre-compositing process and then performing a hot pressing curing process, Wherein, the pre-compositing process adopts a coating process or a coating thermal bonding process or a melt coextrusion process.
The method for preparing an efficient protective composite plate according to claim 7, wherein the hot-press curing process step comprises:

A10), placing the pre-compounded fiber and thermosetting powder coating in a hot pressing device;

A20) hot-pressing the pre-composited fiber and the thermosetting powder coating under the preset hot-pressing conditions, the acrylic powder coating or the super-weather-resistant polyester powder coating is crosslinked and cured on the fiber;

A30), obtaining the high-efficiency protective composite plate;

The heating temperature range of the hot-pressing conditions is 130-220 ° C, the heating time is 8-30 minutes, and the pressure range is 0.01-0.5Mpa.
The application of the high-efficiency protective composite board according to any one of claims 1 to 6, characterized in that it is applied to photovoltaic packaging materials, building materials, and automotive exterior trim materials.
The application of the high-efficiency protective composite board according to claim 9, wherein the high-efficiency protective composite board is used as a light-receiving surface encapsulation layer of the photovoltaic module to obtain a photovoltaic module by applying the photovoltaic packaging material.
The application of the high-efficiency protective composite board according to claim 10, wherein the photovoltaic module comprises a photovoltaic module layer structure, including a light-receiving surface packaging layer, a packaging film layer, a battery string, and a backlight surface packaging layer of the photovoltaic module, wherein The high-efficiency protective composite plate is used as a light-receiving surface encapsulation layer of a photovoltaic module, and a pre-composite fiber and a thermosetting powder coating are used as the backlight-surface encapsulation layer.
A method for applying an efficient protective composite board according to claim 10 or 11, wherein the photovoltaic module layer structure is prepared by a lamination process, and includes the following operation steps:

B10), laying the light-receiving surface packaging layer and the remaining material layers in order;

B20). Cover the high-temperature Teflon cloth on the top and enter the laminator to laminate to obtain the laminate.

B30). Edge cutting the laminate to obtain the photovoltaic module layer structure.
The method for applying an efficient protective composite board according to claim 11, wherein the photovoltaic module layer structure is prepared by a lamination process, and the lamination process includes a first heating stage, a second heating stage, and The third pressure cooling stage. The heating temperature range of the first stage is 110-150 ° C, and the heating time range is 100-600 seconds. The heating temperature range of the second stage is 130-200 ° C, and the heating time range is 100-1200 seconds. ; The cooling temperature range of the third stage is 25-60 ° C, and the applied pressure range is 0.05-0.25Mpa.