CN108682710A - 一种含pbt的五层结构共挤太阳能电池背板及其制备方法 - Google Patents
一种含pbt的五层结构共挤太阳能电池背板及其制备方法 Download PDFInfo
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Abstract
本发明公开一种含PBT的五层结构共挤太阳能电池背板及其制备方法,属于太阳能电池背板技术领域。其包括外耐候层、外粘接层、基材层、内粘接层和内耐候层,外耐候层和基材层通过外粘接层固定在一起,基材层和内耐候层通过内粘接层固定在一起;本发明采用共挤工艺将各层材料熔融于不同流道汇合并直接挤出成型,操作工艺简单,粘接层之间不易分离脱落。本发明制备方法不仅能够简化加工工艺,所制备背板还具有良好的耐候性、机械性能和长期稳定性,同时制备过程中不使用有机溶剂,环保绿色。
Description
技术领域
本发明属于太阳能电池背板领域,具体涉及一种含PBT的五层结构共挤太阳能电池背板及其制备方法。
背景技术
近年来由于全球环境问题和化石燃料的枯竭,太阳能作为一种清洁无污染、资源最丰富的可再生能源而受到人们的广泛关注。太阳能电池是能够把太阳能直接转化为电能的有效装置。太阳能电池在长期的室外风吹雨淋,紫外线等自然因素的侵蚀环境下,太阳能电池背板应该使用具有优异的耐候性和耐久性的背板,便于保护太阳能电池,延长其使用寿命。
目前市场主流的太阳能电池背板具有五层结构,外层采用具有优异耐候性和抗环境侵蚀性的含氟材料;中间层选用聚对苯二甲酸乙二醇酯(PET),用于提高背板的绝缘性和力学性能;内层为含氟材料或聚烯烃层。但PET结晶速度慢,存在后结晶的问题,必须通过双向拉伸工艺成型,也存在阻隔性能不足的缺陷,而且,含氟材料表面能低,促使其表面光滑、抗摩擦性极好,这既是这类材料的优点也是其缺点,含氟材料作为外耐候层难与PET基材层粘接,在现有技术中多采用聚氨酯或EVA粘结剂以涂覆的方式将两种薄膜复合。这种生产工艺需先对基材层表面一侧涂覆聚氨酯或EVA粘接剂,待其固化烘干后,再对其另一侧涂覆粘接剂后与其他膜层复合,整个工艺复杂,操作周期长,且在生产过程中伴随有机溶剂的挥发,污染环境。另外,层间粘接层长期在大气环境下易失效,造成层间分离和脱落,使太阳能电池背板丧失保护作用。对比之下,聚对苯二甲酸丁二醇酯(PBT)树脂具有结晶速度快,耐热性好,水汽阻隔性好,尺寸稳定性佳、介电强度高等优点,一直以来作为工程用塑料受到了关注,广泛应用在汽车部件、电气电子行业,其单体结构中比PET多了两个碳原子,其分子链更柔顺,更容易结晶。
宁波长阳科技有限公司的专利号为Z201110380482.4公开了一种太阳能电池背板及其制备方法,该背板采用PETG为耐候层、PET为结构增强层、EVOH为阻隔层进行多层共挤,无需使用粘接剂,但PETG材料的耐候性和抗环境侵蚀性远远不及含氟材料,同时各层之间不采用粘接剂在长时间的使用下,也容易出现层与层之间脱落分离现象。
申请人的股东杭州福膜新材料科技股份有限公司拥有申请号为201010536756.X的中国专利,其公开了一种聚偏氟乙烯薄膜专用料,可以用于制备耐候性优异、低水蒸汽透过率、力学性能优异的聚偏氟乙烯薄膜,应用到太阳能电池背板中可实现非常好的效果。
发明内容
本发明的目的在于克服现有技术中存在的不足,提供一种含PBT的五层结构共挤太阳能电池背板及其制备方法,采用熔融共挤工艺成型,不再采用传统的涂覆工艺,能够在保证产品优异性能的同时,降低生产成本,简化制备工艺,增强各层之间的粘接性,不易出现分层或脱落,保证太阳能电池背板的长期耐候性,简化加工工艺流程。
为达到上述发明目的,本发明采用的技术方案是:
一种含PBT的五层结构共挤太阳能电池背板,其特征在于,包括外耐候层、外粘接层、基材层、内粘接层和内耐候层,外耐候层和基材层通过外粘接层固定在一起,基材层和内耐候层通过内粘接层固定在一起;
所述外耐候层为改性聚偏氟乙烯层,按重量份数包括60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定助剂;
所述外粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物或聚氨酯中任一种;
所述基材层为改性聚对苯二甲酸丁二醇酯层,按重量份数包括50-90份聚对苯二甲酸丁二醇酯、5-30份纳米钛白粉、5-40份增韧剂、0.1-2份抗氧剂;
所述内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种;
所述内耐候层为改性聚偏氟乙烯层或改性聚乙烯层;所述改性聚偏氟乙烯层按重量份数包括:60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定剂;所述改性聚乙烯层按重量份数包括:65-85份线性低密度聚乙烯、10-25份低密度聚乙烯、1-5份EVA弹性体、3-5份钛白粉、0.1-2份抗氧剂、0.1-1份光稳定剂。
本发明所述内耐候层为改性聚偏氟乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种;所述内耐候层为改性聚乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种。
本发明所述外耐候层和内耐候层中,所述流动改性剂均为邻苯二甲酸酯二甲酯、邻苯二甲酸酯二乙酯、邻苯二甲酸酯二丁酯、邻苯二甲酸酯二己酯、邻苯二甲酸酯二辛酯、邻苯二甲酸酯二异辛酯、邻苯二甲酸二环己酯、磷酸三乙酯、磷酸三丁酯、磷酸三辛酯任一种或任几种的组合。
本发明所述外粘接层和内粘接层中,所述丙烯酸酯为丙烯酸甲酯、丙烯酸乙酯、丙烯酸丁酯、丙烯酸异辛酯、甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸二甲氨基乙酯中任一种或任几种。
本发明所述外耐候层和内耐候层中,所述无机填料为二氧化硅、二氧化钛、碳酸钙、硫酸钡、硫化锌中的任一种或任几种;所述纳米级填料为纳米级二氧化硅和/或纳米级碳酸钙。
本发明所述的改性聚乙烯层中,抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT中任一种,光稳定剂为光稳定剂770、光稳定剂292、光稳定剂622LD、光稳定剂944中任一种。
本发明所述外耐候层和内耐候层中,所述的增强树脂为丙烯酸酯类树脂和/或甲基丙烯酸酯类树脂。
本发明所述外耐候层和内耐候层中,所述热稳定剂为二月桂酸二丁基锡、马来酸二正辛基锡、双(马来酸单丁酯)二丁基锡、双(月桂硫醇)二丁基锡、S,S’-双(硫代甘醇酸异辛酯)二丁基锡、二月桂酸二正辛基锡、硬脂酸钙、硬脂酸镁、硬脂酸锂、硬脂酸锌、硬脂酸铝、双硬脂酸铝、月桂酸钙、月桂酸锌、蓖麻醇酸钙、2- 乙基己酸锌中的任一种或任几种。
本发明所述改性聚对苯二甲酸丁二醇酯层中,所述增韧剂为甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物、乙烯-丙烯酸丁酯-甲基丙烯酸缩水甘油酯三元共聚物、马来酸酐接枝乙烯-辛烯共聚物中任一种;抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT、抗氧剂DLTP中的任一种。
一种含PBT的五层结构共挤太阳能电池背板的制备方法,其特征在于,具体包括下述步骤:
(1)使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定助剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料,用做外耐候层;
(2)使用高速混合机将聚对苯二甲酸丁二醇酯、纳米钛白粉、增韧剂和抗氧剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚对苯二甲酸丁二醇酯粒料,用做基材层;
(3)所述内耐候层为改性聚偏氟乙烯层时,使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料;
所述内耐候层为改性聚乙烯层时,使用高速混合机将线性低密度聚乙烯、低密度聚乙烯、EVA弹性体、钛白粉、抗氧剂和光稳定剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度180-210℃,得到改性聚乙烯粒料;
(4)将步骤1-3所得到的各层粒料与外粘接层料、内粘接层料分别加入各自挤出机中,熔融塑化后通过各自流道在模头内汇合挤出成复合薄膜,经冷却辊挤压、冷却、牵引、切边、收卷制成所述的含PBT的五层结构共挤太阳能电池背板。
本发明与现有技术相比,具有以下优点和效果:
1、选用聚对苯二甲酸丁二醇酯层作为基材层,PBT结晶速度更快,且具有优良的耐热性能和落沙耐磨性、尺寸稳定性好,因太阳能电池背板具有优良的落沙耐磨性、尺寸稳定性和耐热性能;
2、外粘接层和内粘接层为共聚物层,制备过程中无需使用溶剂溶解粘接剂,也不存在后期的溶剂挥发,避免了传统制备过程对环境带来的安全和环保问题;
3、五层结构通过熔融共挤的方式结合在一起,粘接层与基材层、耐候层表面存在熔融和化学反应,各层之间粘接更为牢固,不易出现传统涂布方式的粘接层厚度不匀、分层脱落等现象,产品的耐候性优良、更能在较长时间内满足太阳能电池背板产品耐候性的需要,保证太阳能电池的使用效率;
4、采用多层共挤的形式制备太阳能电池背板,突破传统的制备工艺,避免粘接层涂布与基材层的过程,操作工艺简单化,且背板各层厚度、性能可控可调,易于实现大规模、自动化、连续化的生产,生产效率高,是一种性能优异的新型太阳能电池背板,该背板还具有良好的耐候性、机械性能和长期稳定性,同时制备过程中不使用有机溶剂,环保绿色。
具体实施方式
下面通过实施例对本发明作进一步的详细说明,以下实施例是对本发明的解释而本发明并不局限于以下实施例。
一种含PBT的五层结构共挤太阳能电池背板,包括外耐候层、外粘接层、基材层、内粘接层和内耐候层,外耐候层和基材层通过外粘接层固定在一起,基材层和内耐候层通过内粘接层固定在一起。
外耐候层为改性聚偏氟乙烯层,按重量份数包括60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定助剂;进一步的,聚偏氟乙烯的重量份数的具体数值为60-75之间的任一整数;纳米级填料的重量份数的具体数值为5-10之间的任一整数;流动改性剂的重量份数的具体数值为0.1×A,A的取值范围为5-35之间的任一整数;增强树脂的重量份数的具体数值为10-20之间的任一整数;无机填料的重量份数的具体数值为5-10之间的任一整数;热稳定助剂的重量份数的具体数值为0.1×B,B的取值范围为1-20之间的任一整数。
外粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物或聚氨酯中任一种。
基材层为改性聚对苯二甲酸丁二醇酯层,按重量份数包括50-90份聚对苯二甲酸丁二醇酯、5-30份纳米钛白粉、5-40份增韧剂、0.1-2份抗氧剂;进一步的,聚对苯二甲酸丁二醇酯的重量份数的具体数值为50-90之间的任一整数;纳米钛白粉的重量份数的具体数值为5-30之间的任一整数;增韧剂的重量份数的具体数值为5-40之间的任一整数;抗氧剂的重量份数的具体数值为0.1×C,C的取值范围为1-20之间的任一整数。
内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种。
内耐候层为改性聚偏氟乙烯层或改性聚乙烯层;改性聚偏氟乙烯层按重量份数包括:60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定剂;改性聚乙烯层按重量份数包括:65-85份线性低密度聚乙烯、10-25份低密度聚乙烯、1-5份EVA弹性体、3-5份钛白粉、0.1-2份抗氧剂、0.1-1份光稳定剂。进一步的,改性聚偏氟乙烯层中,聚偏氟乙烯的重量份数的具体数值为60-75之间的任一整数;纳米级填料的重量份数的具体数值为5-10之间的任一整数;流动改性剂的重量份数的具体数值为0.1×E,E的取值范围为5-35之间的任一整数;增强树脂的重量份数的具体数值为10-20之间的任一整数;无机填料的重量份数的具体数值为5-10之间的任一整数;热稳定剂的重量份数的具体数值为0.1×F,F的取值范围为1-20之间的任一整数。进一步的,改性聚乙烯层中,线性低密度聚乙烯的重量份数的具体数值为65-85之间的任一整数;低密度聚乙烯的重量份数的具体数值为10-25之间的任一整数;EVA弹性体的重量份数的具体数值为1-5之间的任一整数;钛白粉的重量份数的具体数值为3-5之间的任一整数;抗氧剂的重量份数的具体数值为0.1×G,G的取值范围为1-20之间的任一整数;光稳定剂的重量份数的具体数值为0.1×H,H的取值范围为1-10之间的任一整数。
内耐候层为改性聚偏氟乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种;内耐候层为改性聚乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种。
外耐候层和内耐候层中,所述流动改性剂均为邻苯二甲酸酯二甲酯、邻苯二甲酸酯二乙酯、邻苯二甲酸酯二丁酯、邻苯二甲酸酯二己酯、邻苯二甲酸酯二辛酯、邻苯二甲酸酯二异辛酯、邻苯二甲酸二环己酯、磷酸三乙酯、磷酸三丁酯、磷酸三辛酯任一种或任几种的组合。
外粘接层和内粘接层中,所述丙烯酸酯选自丙烯酸甲酯、丙烯酸乙酯、丙烯酸丁酯、丙烯酸异辛酯、甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸二甲氨基乙酯中任一种或任几种。
外耐候层和内耐候层中,所述无机填料为二氧化硅、二氧化钛、碳酸钙、硫酸钡、硫化锌中的任一种或任几种;所述纳米级填料为纳米级二氧化硅和/或纳米级碳酸钙。
改性聚乙烯层中,抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT中任一种,光稳定剂为光稳定剂770、光稳定剂292、光稳定剂622LD、光稳定剂944中任一种。
外耐候层和内耐候层中,所述的增强树脂为丙烯酸酯类树脂和/或甲基丙烯酸酯类树脂。
外耐候层和内耐候层中,所述热稳定剂为二月桂酸二丁基锡、马来酸二正辛基锡、双(马来酸单丁酯)二丁基锡、双(月桂硫醇)二丁基锡、S,S’-双(硫代甘醇酸异辛酯)二丁基锡、二月桂酸二正辛基锡、硬脂酸钙、硬脂酸镁、硬脂酸锂、硬脂酸锌、硬脂酸铝、双硬脂酸铝、月桂酸钙、月桂酸锌、蓖麻醇酸钙、2- 乙基己酸锌中的任一种或任几种。
改性聚对苯二甲酸丁二醇酯层中,所述增韧剂为甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物、乙烯-丙烯酸丁酯-甲基丙烯酸缩水甘油酯三元共聚物、马来酸酐接枝乙烯-辛烯共聚物中任一种;抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT、抗氧剂DLTP中的任一种。
乙烯-醋酸乙烯共聚物中醋酸乙烯含量为35-55%。
改性聚偏氟乙烯层中,所述聚偏氟乙烯的分子量为20-100万。
改性聚对苯二甲酸丁二醇酯层中,所述聚对苯二甲酸丁二醇酯的特性粘度为0.5-1.3dL/g。
丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物与聚偏氟乙烯热力学相容,甲基丙烯酸缩水甘油酯中带有环氧官能团,可以与聚对苯二甲酸丁二醇酯发生官能团反应,因此所得的胶黏层可以对外耐候层聚偏氟乙烯和基材层聚对苯二甲酸丁二醇酯层起到较强粘结作用,不易脱落。
由于乙烯-醋酸乙烯共聚物自身凝聚力大,熔融表面张力小,具有良好的粘合性,能够将聚偏氟乙烯和聚对苯二甲酸丁二醇酯粘接在一起。
由于聚氨酯结构中含有极性基团,能够被粘接材料之间产生氢键作用使粘接更加牢固。
一种根据权利要求含PBT的五层结构共挤太阳能电池背板的制备方法,其特征在于,具体包括下述步骤:
(1)使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定助剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料,用做外耐候层;
(2)使用高速混合机将聚对苯二甲酸丁二醇酯、纳米钛白粉、增韧剂和抗氧剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚对苯二甲酸丁二醇酯粒料,用做基材层;
(3)所述内耐候层为改性聚偏氟乙烯层时,使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料;
所述内耐候层为改性聚乙烯层时,使用高速混合机将线性低密度聚乙烯、低密度聚乙烯、EVA弹性体、钛白粉、抗氧剂和光稳定剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度180-210℃,得到改性聚乙烯粒料;
(4)将步骤1-3所得到的各层粒料与外粘接层料、内粘接层料分别加入各自挤出机中,熔融塑化后通过各自流道在模头内汇合挤出成复合薄膜,经冷却辊挤压、冷却、牵引、切边、收卷制成所述的含PBT的五层结构共挤太阳能电池背板。
实施例:
下述实施例中改性聚偏氟乙烯层配方中纳米级填料为纳米碳酸钙,流动改性剂为邻苯二甲酸二辛酯(DOP),增强树脂为一种甲基丙烯酸甲酯树脂与一种丙烯酸树脂的组合,无机填料为二氧化钛(TiO2),热稳定剂为马来酸二丁基锡(DBTM)与硬脂酸钙的组合。改性聚对苯二甲酸丁二醇酯配方中增韧剂为甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物,抗氧剂为抗氧剂1010。改性聚乙烯配方中抗氧剂为抗氧剂1010,光稳定剂为光稳定剂770。
实施例1
一种含PBT的五层结构共挤太阳能电池背板,其具体制备过程如下:
(1)采用高速混合机将按重量份数的75份聚偏氟乙烯、5份纳米碳酸钙、3.5份DOP、4份甲基丙烯酸树脂、6份丙烯酸树脂、5份TiO2、1份DBTM、0.5份硬脂酸钙在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出,挤出温度为200-230℃,螺杆转速200-350rpm,挤出后造粒制得改性聚偏氟乙烯粒料;
(2)采用高速混合机将按重量份数的50份聚对苯二甲酸丁二醇酯、20份纳米钛白粉、29份甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物和1份抗氧剂1010在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出,挤出温度为200-230℃,螺杆转速200-350rpm,挤出后造粒制得改性聚对苯二甲酸丁二醇酯粒料;
(3)按照外耐候层、外粘接层、基材层、内粘接层、内耐候层分别为改性聚偏氟乙烯层粒料、甲基丙烯酸缩水甘油酯-甲基丙烯酸甲酯共聚物料、改性聚对苯二甲酸丁二醇酯料、甲基丙烯酸缩水甘油酯-甲基丙烯酸甲酯共聚物料、改性聚偏氟乙烯层粒料,将各层料分别加入各自挤出机中,熔融塑化后通过各自流道在模头内汇合挤出成复合薄膜,经冷却辊挤压、冷却、牵引、切边、收卷制成所述的含PBT的五层结构共挤太阳能电池背板。
实施例2
一种含PBT的五层结构共挤太阳能电池背板,其具体制备过程如下:
(1)采用高速混合机将按重量份数的75份聚偏氟乙烯、5份纳米碳酸钙、3.5份DOP、4份甲基丙烯酸树脂、6份丙烯酸树脂、5份TiO2、1份DBTM、0.5份硬脂酸钙在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出,挤出温度为200-230℃,螺杆转速200-350rpm,挤出后造粒制得改性聚偏氟乙烯层粒料;
(2)采用高速混合机将按重量份数的50份聚对苯二甲酸丁二醇酯、20份纳米钛白粉、29份甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物和1份抗氧剂1010在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出,挤出温度为200-230℃,螺杆转速200-350rpm,挤出后造粒制得改性聚对苯二甲酸丁二醇酯粒料;
(3)采用高速混合机将按重量份数的70份线性低密度聚乙烯、20份低密度聚乙烯、5份EVA弹性体、3.5份钛白粉、1份抗氧剂1010、0.5份光稳定剂7700在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出,挤出温度为180-210℃,螺杆转速180-300rpm,挤出后造粒制得改性聚乙烯粒料;
(4)按照外耐候层、外粘接层、基材层、内粘接层、内耐候层分别为改性聚偏氟乙烯层粒料、甲基丙烯酸缩水甘油酯-甲基丙烯酸甲酯共聚物料、改性聚对苯二甲酸丁二醇酯料、乙烯-甲基丙烯酸缩水甘油酯共聚物料、改性聚乙烯粒料,将各层料分别加入各自挤出机中,熔融塑化后通过各自流道在模头内汇合挤出成复合薄膜,经冷却辊挤压、冷却、牵引、切边、收卷制成所述的含PBT的五层结构共挤太阳能电池背板。
此外,需要说明的是,本说明书中所描述的具体实施例,其零部件的形状、所取名称等可以不同,本说明书中所描述的以上内容仅仅是对本发明结构所作的举例说明。凡依据本发明专利构思所述的构造、特征及原理所做的等效变化或者简单变化,均包括于本发明专利的保护范围内。本发明所属技术领域的技术人员可以对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代,只要不偏离本发明的结构或者超越本权利要求书所定义的范围,均应属于本发明的保护范围。
Claims (10)
1.一种含PBT的五层结构共挤太阳能电池背板,其特征在于,包括外耐候层、外粘接层、基材层、内粘接层和内耐候层,外耐候层和基材层通过外粘接层固定在一起,基材层和内耐候层通过内粘接层固定在一起;
所述外耐候层为改性聚偏氟乙烯层,按重量份数包括60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定助剂;
所述外粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物或聚氨酯中任一种;
所述基材层为改性聚对苯二甲酸丁二醇酯层,按重量份数包括50-90份聚对苯二甲酸丁二醇酯、5-30份纳米钛白粉、5-40份增韧剂、0.1-2份抗氧剂;
所述内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种;
所述内耐候层为改性聚偏氟乙烯层或改性聚乙烯层;所述改性聚偏氟乙烯层按重量份数包括:60-75份聚偏氟乙烯、5-10份纳米级填料、0.5-3.5份流动改性剂、10-20份增强树脂、5-10份无机填料、0.1-2份热稳定剂;所述改性聚乙烯层按重量份数包括:65-85份线性低密度聚乙烯、10-25份低密度聚乙烯、1-5份EVA弹性体、3-5份钛白粉、0.1-2份抗氧剂、0.1-1份光稳定剂。
2.根据权利要求1所述的含PBT的五层结构共挤太阳能电池背板,其特征在于,所述内耐候层为改性聚偏氟乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种;所述内耐候层为改性聚乙烯层时,内粘接层为丙烯酸酯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-甲基丙烯酸缩水甘油酯共聚物层、乙烯-醋酸乙烯共聚物层、聚氨酯层中任一种。
3.根据权利要求1所述的含PBT的五层结构共挤太阳能电池背板,其特征在于,所述外耐候层和内耐候层中,所述流动改性剂均为邻苯二甲酸酯二甲酯、邻苯二甲酸酯二乙酯、邻苯二甲酸酯二丁酯、邻苯二甲酸酯二己酯、邻苯二甲酸酯二辛酯、邻苯二甲酸酯二异辛酯、邻苯二甲酸二环己酯、磷酸三乙酯、磷酸三丁酯、磷酸三辛酯任一种或任几种的组合。
4.根据权利要求1所述的含PBT的五层结构共挤太阳能电池背板,其特征在于,所述外粘接层和内粘接层中,所述丙烯酸酯为丙烯酸甲酯、丙烯酸乙酯、丙烯酸丁酯、丙烯酸异辛酯、甲基丙烯酸甲酯、甲基丙烯酸乙酯、甲基丙烯酸丁酯、甲基丙烯酸二甲氨基乙酯中任一种或任几种。
5.根据权利要求1所述的五层结构共挤太阳能电池背板,其特征在于:所述外耐候层和内耐候层中,所述无机填料为二氧化硅、二氧化钛、碳酸钙、硫酸钡、硫化锌中的任一种或任几种;所述纳米级填料为纳米级二氧化硅和/或纳米级碳酸钙。
6.根据权利要求1所述的五层结构共挤太阳能电池背板,其特征在于:所述的改性聚乙烯层中,抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT中任一种,光稳定剂为光稳定剂770、光稳定剂292、光稳定剂622LD、光稳定剂944中任一种。
7.根据权利要求1所述的五层结构共挤太阳能电池背板,其特征在于:所述外耐候层和内耐候层中,所述的增强树脂为丙烯酸酯类树脂和/或甲基丙烯酸酯类树脂。
8.根据权利要求1所述的五层结构共挤太阳能电池背板,其特征在于:所述外耐候层和内耐候层中,所述热稳定剂为二月桂酸二丁基锡、马来酸二正辛基锡、双(马来酸单丁酯)二丁基锡、双(月桂硫醇)二丁基锡、S,S’-双(硫代甘醇酸异辛酯)二丁基锡、二月桂酸二正辛基锡、硬脂酸钙、硬脂酸镁、硬脂酸锂、硬脂酸锌、硬脂酸铝、双硬脂酸铝、月桂酸钙、月桂酸锌、蓖麻醇酸钙、2- 乙基己酸锌中的任一种或任几种。
9.根据权利要求1所述的五层结构共挤太阳能电池背板,其特征在于:所述改性聚对苯二甲酸丁二醇酯层中,所述增韧剂为甲基丙烯酸甲酯-丁二烯-苯乙烯三元共聚物、乙烯-丙烯酸丁酯-甲基丙烯酸缩水甘油酯三元共聚物、马来酸酐接枝乙烯-辛烯共聚物中任一种;抗氧剂为抗氧剂1010、抗氧剂168、抗氧剂264、抗氧剂BHT、抗氧剂DLTP中的任一种。
10.一种根据权利要求1-9任一项权利要求所述的含PBT的五层结构共挤太阳能电池背板的制备方法,其特征在于,具体包括下述步骤:
(1)使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定助剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料,用做外耐候层;
(2)使用高速混合机将聚对苯二甲酸丁二醇酯、纳米钛白粉、增韧剂和抗氧剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚对苯二甲酸丁二醇酯粒料,用做基材层;
(3)所述内耐候层为改性聚偏氟乙烯层时,使用高速混合机将聚偏氟乙烯、纳米级填料、流动改性剂、增强树脂、无机填料和热稳定剂常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度200-230℃,螺杆转速200-350rpm,得到改性聚偏氟乙烯粒料;
所述内耐候层为改性聚乙烯层时,使用高速混合机将线性低密度聚乙烯、低密度聚乙烯、EVA弹性体、钛白粉、抗氧剂和光稳定剂在常温下机械混合5-10分钟后,采用双螺杆挤出机进行熔融挤出造粒,挤出温度180-210℃,得到改性聚乙烯粒料;
(4)将步骤1-3所得到的各层粒料与外粘接层料、内粘接层料分别加入各自挤出机中,熔融塑化后通过各自流道在模头内汇合挤出成复合薄膜,经冷却辊挤压、冷却、牵引、切边、收卷制成所述的含PBT的五层结构共挤太阳能电池背板。
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