CN114437643A - 一种新型轻质光伏组件封装板 - Google Patents
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Abstract
本发明公开了一种新型轻质光伏组件封装板,从外至内依次包括空气面层、粘接层、基材层和胶膜结合层,所述基材层材料包括以下重量份数组分:基体树脂50~99份,增强填料0.1~50份,耐水解剂0.1~3份,紫外吸收剂0.1~3份,光稳定剂0.1~3份,其他助剂0.1~35份,其中,所述基体树脂选自聚对苯二甲酸乙二醇酯、聚甲基丙烯酸甲酯、聚碳酸酯、聚对苯二甲酸丁二酯、环状聚烯烃、环烯烃聚合物、聚丙烯、尼龙、聚乙烯中的任意一种或多种混合物;所述增强填料选自金属纤维、碳纤维、塑料纤维、玻璃纤维的任意一种或多种的混合物。本发明具有重量轻、耐候性高、强度高,抗冲击性好,以及可靠性高的优点。
Description
技术领域
本发明属于光伏发电组件密封技术领域,尤其涉及高分子聚合物光伏电板封装轻质组件。
背景技术
自双碳目标提出后,分布式光伏发电迎来蓬勃发展,与集中式发电相比,分布式场景更为复杂,传统的组件封装方案多采用玻璃或玻璃与高分子材料的组合,其重量通常在20-30㎏,再加上支架等辅助部件重量超过30Kg,在分布式光伏(尤其是BAPV、BIPV)上使用很受限制,比如一些老旧的彩钢屋顶,如果安装重量过大,存在一定的安全隐患和安装不便。
目前为了解决上述存在的技术问题,常规技术通常是将光伏组件的上下外层结构替换成高分子材料的光伏背板。而现有的高分子光伏背板材料多采用PET或聚烯烃作为基材(多为4或5层结构),但随之带来背板强度不够,耐候性差等问题,因而只能通过增加层数弥补背板强度的不够,由原来的4~5层结构增至9层甚至更多。由于结构层数的增加,造成背板生产工序的复杂化,增加了背板的重量,提高了背板的生产成本,且设备匹配性变差。
发明内容
针对现有技术中存在的问题和缺陷,本发明提供了一种新型轻质光伏组件封装板,具有重量轻、耐候性高、强度高,抗冲击性好,以及可靠性高的优点。
为解决上述技术问题,本发明采用了以下技术方案:一种新型轻质光伏组件封装板,从外至内依次包括空气面层、粘接层、基材层和胶膜结合层,其中:
所述基材层材料由以下重量份数组分混合后,经过挤出成型、溶液流延成型或压延成型制得:
基体树脂 50~99份
增强填料 0.1~50份
耐水解剂 0.1~3份
紫外吸收剂 0.1~3份
光稳定剂 0.1~3份
其他助剂 0.1~35份
其中,所述基体树脂选自聚对苯二甲酸乙二醇酯、聚甲基丙烯酸甲酯、聚碳酸酯、聚对苯二甲酸丁二酯、环状聚烯烃、环烯烃聚合物、聚丙烯、尼龙、聚乙烯中的任意一种或多种混合物;所述增强填料选自金属纤维、碳纤维、塑料纤维、玻璃纤维的任意一种或多种的混合物。
作为优选,所述其他助剂包括耐水解剂、增粘剂、吸酸剂、热稳定剂、抗氧剂、填料、着色剂中的至少一种。所述耐水解剂为聚碳化二亚胺、环氧聚合物、碳化二亚胺、双(2,6-二异丙基苯基)碳二亚胺、二环己基碳二亚胺、二异丙基碳二亚胺中的任意一种或或多种的混合物。
作为优选,所述紫外吸收剂选自邻羟基二苯甲酮类、苯并***类、水杨酸酯类、三嗪类、取代丙烯腈类中的任意一种或至少两种的混合物。
作为优选,所述光稳定剂选自光屏蔽剂类、淬灭剂类、自由基捕获剂类、氢过氧化物分解剂类中的的任意一种或至少两种的混合物。
作为优选,所述空气面层材料由含氟树脂与其他助剂混合后经过挤出成型、溶液流延成型或压延成型制得,所述含氟树脂为偏氟乙烯、乙烯-四氟乙烯共聚物、聚三氟氯乙烯、四氟乙烯-六氟丙烯共聚物、氟乙烯、聚四氟乙烯或乙烯-三氟氯乙烯共聚物中的任意一种或两种的混合物。
作为优选,所述空气面层材料中还含有紫外吸收剂和光稳定剂。
作为优选,所述粘接层由粘接材料与所述紫外吸收剂、所述光稳定剂和所述其他助剂混合后经过挤出成型、溶液流延成型或压延成型制得。
作为优选,所述粘接材料为聚氨基甲酸酯、聚甲基丙烯酸甲酯、聚甲基丙烯酸羟乙酯、乙烯-乙烯醇共聚物、乙烯-甲基丙烯酸共聚物、乙基甲基丙烯酸酯共聚物、甲基丙烯酸缩水甘油酯接枝聚烯烃弹性体、甲基丙烯酸缩水甘油酯接枝聚乙烯、马来酸酐接枝聚烯烃弹性体、马来酸酐接枝聚乙烯中的任意一种或至少两种的混合物。
作为优选,所述空气面层厚度为15~80μm,优选20~30μm;所述基材层的厚度为10~1000μm,优选50~400μm;所述粘接层厚度为6~20μm。
作为优选,所述胶膜结合层选自涂层、热熔胶或其他粘接材料,起到助粘接作用。
作为优选,所述空气面层和基材层分别经过挤出成型、溶液流延成型或压延成型方式制得膜层,制得的空气面层和基材层之间通过粘接层结合在一起,所述胶膜结合层通过涂布或淋膜方式在基材层的另一面形成。
有益效果:与现有技术相比,本发明具有以下优点:
1、重量轻:本发明采用聚合物前板和聚合物后板封装,比玻璃封装重量减轻70%以上;
2、耐候性高:空气面通过选用含氟树脂,含氟树脂含有碳氟键,由于其局部的离子键特性,在有机化学中,它是最强的单键和相对短小的键其本身耐候性能优异;同时通过紫外吸收剂和光稳定搭配,能够有效的阻止紫外线(阻隔率>98%),保护内部的材料,其耐紫外能力甚至可以做到1500kWh/m2以上;
3、强度高,抗冲击性好:通过基体树脂、增强填料、耐水解剂、紫外吸收剂、光稳定剂以及其他助剂的搭配,提高了基材的强度和抗冲击性;
4、可靠性高:通过各层材料的设计以及多层材料通过粘接剂结合,本发明提供的聚合物前板和聚合物后板在使用过程中不会产生开裂、分层、发黄等不良。
附图说明
图1为本发明所述新型轻质光伏组件的结构示意图;
图2为本发明所述新型轻质光伏组件封装板的结构示意图。
图中,聚合物前板1、胶膜2、电池片3、胶膜4、聚合物后板5、空气面层A、粘接层B,基材层C、胶膜结合层D。
具体实施方式
下面结合附图和具体实施例,进一步阐明本发明。应理解这些实施例仅用于说明本发明而不用于限制本发明的范围,在阅读了本发明之后,本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定的范围。
实施例1:聚合物前板
作为聚合物前板,从外到内依次为空气面(25μm,透明淡蓝色)、粘接层(8μm)、基材层(600μm)、胶膜结合面(5μm),其中:
按重量计,空气面包含如下组分:
含氟树脂 85份
紫外吸收剂 0.6份
光稳定剂 0.3份
其他助剂 14.1份;
其中含氟树脂为聚偏氟乙烯,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为14份PMMA,0.05份1010,0.05份吸酸剂;
其中,按重量计,粘结层包含如下组分:
粘结材料 99.5份
紫外吸收剂 0.2份
光稳定剂 0.1份
其他助剂; 0.2份
其中粘结材料为聚氨酯,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为1010;
其中,按重量计,基材层包含如下组分:
基体树脂 93份
增强填料 5份
耐水解剂 0.5份
紫外吸收剂 0.6份
光稳定剂 0.3份
其他助剂; 0.6份
其中基体树脂为聚对苯二甲酸乙二醇酯,增强填料为玻璃纤维,耐水解剂为碳化二亚胺,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为1010;
其中胶膜结合面为透明FEVE涂层;
制备方法为将胶膜结合面通过涂布的方式涂布在基材层上,然后在基材层上涂布粘结层,再跟空气面复合,得到聚合物后板。
实施例2:聚合物后板
作为聚合物后板,从外到内依次为空气面(25μm,不透明白色)、粘接层(8μm)、基材层(600μm)、胶膜结合面(5μm),其中:
按重量计,空气面包含如下组分:
含氟树脂 75份
紫外吸收剂 0.6份
光稳定剂 0.3份
其他助剂 24.1份;
其中含氟树脂为聚偏氟乙烯,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为14份PMMA,10份二氧化钛,0.05份1010,0.05份吸酸剂;
其中,按重量计,粘结层包含如下组分:
粘结材料 99.5份
紫外吸收剂 0.2份
光稳定剂 0.1份
其他助剂; 0.2份
其中粘结材料为聚氨酯,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为1010;
其中,按重量计,基材层包含如下组分:
基体树脂 83份
增强填料 5份
耐水解剂 0.5份
紫外吸收剂 0.6份
光稳定剂 0.3份
其他助剂; 10.6份
其中基体树脂为聚对苯二甲酸乙二醇酯,增强填料为玻璃纤维,耐水解剂为碳化二亚胺,紫外吸收剂为UV234,光稳定剂为UV770,其他助剂为10份二氧化钛,0.6份1010;
其中胶膜结合面为白色FEVE涂层;
制备方法为将胶膜结合面通过涂布的方式涂布在基材层上,然后在基材层上涂布粘结层,再跟空气面复合,得到聚合物后板。
Claims (10)
1.一种新型轻质光伏组件封装板,其特征在于:从外至内依次包括空气面层、粘接层、基材层和胶膜结合层,其中:
所述基材层材料由以下重量份数组分混合后,经过挤出成型、溶液流延成型或压延成型制得:
基体树脂 50~99份
增强填料 0.1~50份
耐水解剂 0.1~3份
紫外吸收剂 0.1~3份
光稳定剂 0.1~3份
其他助剂 0.1~35份
其中,所述基体树脂选自聚对苯二甲酸乙二醇酯、聚甲基丙烯酸甲酯、聚碳酸酯、聚对苯二甲酸丁二酯、环状聚烯烃、环烯烃聚合物、聚丙烯、尼龙、聚乙烯中的任意一种或多种混合物;所述增强填料选自金属纤维、碳纤维、塑料纤维、玻璃纤维的任意一种或多种的混合物。
2.根据权利要求1所述新型轻质光伏组件封装板,其特征在于:所述其他助剂包括耐水解剂、增粘剂、吸酸剂、热稳定剂、抗氧剂、填料、着色剂中的至少一种;
所述耐水解剂为聚碳化二亚胺、环氧聚合物、碳化二亚胺、双(2,6-二异丙基苯基)碳二亚胺、二环己基碳二亚胺、二异丙基碳二亚胺中的任意一种或或多种的混合物。
3.根据权利要求1所述新型轻质光伏组件封装板,其特征在于:所述紫外吸收剂选自邻羟基二苯甲酮类、苯并***类、水杨酸酯类、三嗪类、取代丙烯腈类中的任意一种或至少两种的混合物。
4.根据权利要求1所述新型轻质光伏组件封装板,其特征在于:所述光稳定剂选自光屏蔽剂类、淬灭剂类、自由基捕获剂类、氢过氧化物分解剂类中的的任意一种或至少两种的混合物。
5.根据权利要求1所述新型轻质光伏组件封装板,其特征在于:所述空气面层材料由含氟树脂与其他助剂混合后经过挤出成型、溶液流延成型或压延成型制得,所述含氟树脂为偏氟乙烯、乙烯-四氟乙烯共聚物、聚三氟氯乙烯、四氟乙烯-六氟丙烯共聚物、氟乙烯、聚四氟乙烯或乙烯-三氟氯乙烯共聚物中的任意一种或两种的混合物。
6.根据权利要求5所述新型轻质光伏组件封装板,其特征在于:所述空气面层材料中还含有紫外吸收剂和光稳定剂。
7.根据权利要求5所述新型轻质光伏组件封装板,其特征在于:所述粘接层由粘接材料与所述紫外吸收剂、所述光稳定剂和所述其他助剂混合后经过挤出成型、溶液流延成型或压延成型制得。
8.根据权利要求7所述新型轻质光伏组件封装板,其特征在于:所述粘接材料为聚氨基甲酸酯、聚甲基丙烯酸甲酯、聚甲基丙烯酸羟乙酯、乙烯-乙烯醇共聚物、乙烯-甲基丙烯酸共聚物、乙基甲基丙烯酸酯共聚物、甲基丙烯酸缩水甘油酯接枝聚烯烃弹性体、甲基丙烯酸缩水甘油酯接枝聚乙烯、马来酸酐接枝聚烯烃弹性体、马来酸酐接枝聚乙烯中的任意一种或至少两种的混合物。
9.根据权利要求1所述新型轻质光伏组件封装板,其特征在于:所述空气面层厚度为15~80μm,优选20~30μm;所述基材层的厚度为10~1000μm,优选50~400μm;所述粘接层厚度为6~20μm;所述胶膜结合层选自涂层、热熔胶或其他粘接材料,起到助粘接作用。
10.根据权利要求1~9任一所述新型轻质光伏组件封装板,其特征在于:所述空气面层和基材层分别经过挤出成型、溶液流延成型或压延成型方式制得膜层,制得的空气面层和基材层之间通过粘接层结合在一起,所述胶膜结合层通过涂布或淋膜方式在基材层的另一面形成。
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