CN105161560A - 一种太阳能电池绝缘片 - Google Patents
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Abstract
本发明公开了一种太阳能电池绝缘片，包括内层、设置在内层两侧的外层，内层和外层之间设置有过渡层，所述内层为聚丙烯合金，所述外层为聚乙烯和聚烯烃的合金，所述过渡层为聚丙烯和聚烯烃的合金。与现有技术相比，本发明的有益效果是：1、本发明绝缘片内层为聚丙烯合金层，其耐水解、耐老化性能优良。2、本发明绝缘片外层为聚乙烯类材料，其与EVA封装胶膜具有出色的粘合性。3、本发明绝缘片相对于太阳能背板作绝缘片，绝缘效果好；由于没有昂贵的氟层，成本更低。
Description
技术领域
本发明涉及一种太阳能电池绝缘片。
背景技术
太阳能电池绝缘片设计在光伏组件内部敏感位置发挥绝缘、物理分隔及电池/焊带定位等作用。一片合格的光伏组件需要具有超过25年的使用寿命，并能抵抗各种极端恶劣的天气。因此太阳能电池绝缘片需要具有出色的耐候性及可靠的电气绝缘性，并且与EVA封装胶膜具有出色的粘合性。
现在光伏组件的绝缘片通常采用EVA或者太阳能背板。采用EVA作绝缘片，其封装效果好，但是由于在光伏组件层压过程中EVA的流动会造成EVA绝缘效果不佳。采用太阳能背板作绝缘片价格昂贵，而且传统TPE背板其T面(氟层)与EVA粘合不佳，这样在组件使用过程中，可能会有水汽侵蚀、发生脱层、短路，造成组件发电效率降低，甚至报废。
发明内容
本发明要解决的技术问题是提供一种太阳能电池绝缘片。
本发明是通过以下技术方案来实现：
一种太阳能电池绝缘片，包括内层、设置在内层两侧的外层，内层和外层之间设置有过渡层，所述内层为聚丙烯及其合金，所述外层为聚乙烯和烯烃类共聚物的合金，所述过渡层为聚丙烯与烯烃类共聚物的合金。
进一步，所述聚丙烯及其合金为聚丙烯及其与工程塑料的合金；所述工程塑料为聚酰胺或聚苯醚；所述聚丙烯选自均聚聚丙烯、共聚聚丙烯、嵌段共聚聚丙烯、马来酸酐接枝聚丙烯中的一种或几种。
进一步，所述烯烃类共聚物为乙烯、丙烯酸酯类、甲基丙烯酸缩水甘油酯三者的二元或者三元共聚物，马来酸酐接枝的烯烃类共聚物，POE弹性体中的一种或几种。
进一步，所述马来酸酐接枝的烯烃类共聚物为以下一种或多种的组合：马来酸酐接枝聚乙烯、马来酸酐与乙烯的共聚物、马来酸酐接枝的乙烯-醋酸乙烯酯共聚物、马来酸酐接枝的乙烯-丙烯酸酯共聚物、马来酸酐接枝聚丙烯。
进一步，所述POE弹性体为乙烯、丙烯、丁烯、己烯、辛烯的二元或多元共聚物。
进一步，所述内层、外层、过渡层均添加紫外吸收剂、稳定剂、抗氧化剂和无机填料；所述无机填料选自碳酸钙、二氧化钛、硫酸钡、云母、滑石、高岭土、玻璃微珠和玻璃纤维中的一种。
进一步，所述外层的厚度在10-100微米，所述内层的厚度在10-500微米，所述过渡层的厚度为10-100微米。
进一步，所述外层的厚度在20-50微米，所述内层的厚度在50-300微米，所述过渡层的厚度为20-50微米。
一种太阳能电池绝缘片的制作方法，将外层塑料粒子、内层塑料粒子、过渡层塑料粒子分别通过挤出机挤出到同一模具内，一步成型。
与现有技术相比，本发明的有益效果是：
1、本专利绝缘片内层为聚丙烯合金层，其耐水解、耐老化性能优良。
2、本专利绝缘片外层为聚乙烯类材料，其与EVA封装胶膜具有出色的粘合性。
3、本专利绝缘片相对于太阳能背板作绝缘片，绝缘效果好；由于没有昂贵的氟层，成本更低。
附图说明
图1为本发明的结构示意图。
具体实施方式
下面结合附图和实施例对本发明作进一步说明：
如图1所示，一种太阳能电池绝缘片，为对称结构，由外层1、5，内层3，以及连接外层和内层的两层过渡层2、4组成。
实施例1
外层由聚乙烯、POE弹性体、稳定剂、抗氧化剂和无机填料制成，具体为100份聚乙烯、10份ENGAGE8540、0.3份IrganoxB225和3份TiO2共混，经过挤出机造粒。其中，ENGAGE8540为美国陶氏化学生产的POE弹性体，IrganoxB225为巴斯夫股份公司生产的热稳定剂。
内层为改性聚丙烯和工程塑料的合金，改性聚丙烯则由均聚聚丙烯(均聚PP)和热稳定剂共混改性而成，具体为100份均聚PP、5份的马来酸酐接枝聚丙烯、10份聚酰胺PA和0.3份IrganoxB225共混，经过挤出机造粒。
过渡层由聚丙烯，烯烃类共聚物，热稳定剂和无机填料制成，具体为50份聚丙烯、50份PTW、0.3份IrganoxB225、3份的TiO2共混，经过挤出机造粒。其中，PTW为美国杜邦化工集团(中国)有限公司生产。
将所述外层、内层、过渡层塑料粒子分别通过多层挤出机熔融共挤，即可得到所述太阳能电池绝缘片。五层厚度分别为25/20/200/20/25微米，由此制得的太阳能电池绝缘片总厚度290微米。绝缘片最高***电压为1163V，外层与内层的层间剥离强度为8.8N/cm，Damp-Heat2000小时老化(85℃，85％湿度)后断裂伸长率衰减率为16％。其中，最高***电压参考标准为IEC61730-2:2004，剥离强度测试(180°，0.2m/min剥离速度)参考标准为ASTMD1876，Damp-Heat湿热老化(85℃，85％湿度,2000h)参考标准为IEC61215。
实施例2
外层由聚乙烯、POE弹性体、稳定剂、抗氧化剂和无机填料制成，具体为100份聚乙烯、10份ENGAGE8540、0.3份IrganoxB225和3份TiO2共混，经过挤出机造粒。其中，ENGAGE8540为美国陶氏化学生产的POE弹性体，IrganoxB225为巴斯夫股份公司生产的热稳定剂。
内层为改性聚丙烯和工程塑料的合金，改性聚丙烯则由均聚聚丙烯(均聚PP)和热稳定剂共混改性而成，具体为100份均聚PP、10份聚苯醚PPO和0.3份IrganoxB225共混，经过挤出机造粒。
过渡层由聚丙烯，马来酸酐接枝的聚丙烯，热稳定剂和无机材料制成，具体为50份聚丙烯、50份马来酸酐接枝的聚丙烯、0.3份IrganoxB225、3份的TiO2共混，经过挤出机造粒。
将所述外层、内层、过渡层塑料粒子分别通过多层挤出机熔融共挤，即可得到所述太阳能电池绝缘片。五层厚度分别为25/20/200/20/25微米，由此制得的太阳能电池绝缘片总厚度290微米。绝缘片最高***电压为1255V，外层与内层的层间剥离强度为10.2N/cm，Damp-Heat2000小时老化(85℃，85％湿度)后断裂伸长率衰减率为19％。其中，最高***电压参考标准为IEC61730-2:2004，剥离强度测试(180°，0.2m/min剥离速度)参考标准为ASTMD1876，Damp-Heat湿热老化(85℃，85％湿度，2000h)参考标准为IEC61215。
实施例3
外层由聚乙烯、POE弹性体、稳定剂、抗氧化剂和无机填料制成，具体为100份聚乙烯、10份ENGAGE8540、0.3份IrganoxB225和3份TiO2共混，经过挤出机造粒。其中，ENGAGE8540为美国陶氏化学生产的POE弹性体，IrganoxB225为巴斯夫股份公司生产的热稳定剂。
内层为改性聚丙烯和工程塑料的合金，改性聚丙烯则由均聚聚丙烯(均聚PP)和热稳定剂共混改性而成，具体为100份均聚PP、10份聚苯醚PPO和0.3份IrganoxB225共混，经过挤出机造粒。
过渡层由聚丙烯，马来酸酐接枝的烯烃类共聚物，热稳定剂和无机填料制成，具体为50份聚丙烯、50份Lotader4210、0.3份IrganoxB225、3份的TiO2共混，经过挤出机造粒。其中，Lotader4210为法国阿科玛公司生产的马来酸酐接枝的乙烯-丙烯酸丁酯共聚物。
将所述外层、内层、过渡层塑料粒子分别通过多层挤出机熔融共挤，即可得到所述太阳能电池绝缘片。五层厚度分别为25/20/200/20/25微米，由此制得的太阳能电池绝缘片总厚度290微米。绝缘片最高***电压为1081V，外层与内层的层间剥离强度为9.5N/cm，Damp-Heat2000小时老化(85℃,85％湿度)后断裂伸长率衰减率为18％。其中，最高***电压参考标准为IEC61730-2:2004，剥离强度测试(180°，0.2m/min剥离速度)参考标准为ASTMD1876，Damp-Heat湿热老化(85℃，85％湿度,2000h)参考标准为IEC61215。
凡在不脱离本发明核心的情况下做出的简单的变形或修改均落入本发明的保护范围。
Claims (9)
1.一种太阳能电池绝缘片，其特征在于，包括内层、设置在内层两侧的外层，内层和外层之间设置有过渡层，所述内层为聚丙烯及其合金，所述外层为聚乙烯和烯烃类共聚物的合金，所述过渡层为聚丙烯与烯烃类共聚物的合金。
2.根据权利要求1所述的一种太阳能电池绝缘片，其特征在于，所述聚丙烯及其合金为聚丙烯及其与工程塑料的合金；所述工程塑料为聚酰胺或聚苯醚；所述聚丙烯选自均聚聚丙烯、共聚聚丙烯、嵌段共聚聚丙烯、马来酸酐接枝聚丙烯中的一种或几种。
3.根据权利要求1所述的一种太阳能电池绝缘片，其特征在于，所述烯烃类共聚物为乙烯、丙烯酸酯类、甲基丙烯酸缩水甘油酯三者的二元或者三元共聚物，马来酸酐接枝的烯烃类共聚物，POE弹性体中的一种或几种。
4.根据权利要求3所述的一种太阳能电池绝缘片，其特征在于，所述马来酸酐接枝的烯烃类共聚物为以下一种或多种的组合：马来酸酐接枝聚乙烯、马来酸酐与乙烯的共聚物、马来酸酐接枝的乙烯-醋酸乙烯酯共聚物、马来酸酐接枝的乙烯-丙烯酸酯共聚物、马来酸酐接枝聚丙烯。
5.根据权利要求3所述的一种太阳能电池绝缘片，其特征在于，所述POE弹性体为乙烯、丙烯、丁烯、己烯、辛烯的二元或多元共聚物。
6.根据权利要求1-5任一项所述的一种太阳能电池绝缘片，其特征在于，所述内层、外层、过渡层均添加紫外吸收剂、稳定剂、抗氧化剂和无机填料；所述无机填料选自碳酸钙、二氧化钛、硫酸钡、云母、滑石、高岭土、玻璃微珠和玻璃纤维中的一种。
7.根据权利要求6所述的一种太阳能电池绝缘片，其特征在于，所述外层的厚度在10-100微米，所述内层的厚度在10-500微米，所述过渡层的厚度为10-100微米。
8.根据权利要求7所述的一种太阳能电池绝缘片，其特征在于，所述外层的厚度在20-50微米，所述内层的厚度在50-300微米，所述过渡层的厚度为20-50微米。
9.一种太阳能电池绝缘片的制作方法，其特征在于，将外层塑料粒子、内层塑料粒子、过渡层塑料粒子分别通过挤出机挤出到同一模具内，一步成型。
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