Roof construction method and installation structure of photovoltaic modules

Abstract

The present disclosure relates to a roof construction method and installation structure of a photovoltaic module, the construction method comprising: installing a waterproof layer on a roof, applying an adhesive layer on the waterproof layer, and installing the photovoltaic module on the adhesive layer; wherein a dielectric material layer is further included between the waterproof layer and the adhesive layer, the dielectric material layer comprises a modified polyolefin and a coupling agent, and the waterproof layer comprises polyolefin. The construction method effectively increases the bonding force between the waterproof layer and the adhesive layer by forming a dielectric material layer between the waterproof layer and the adhesive layer, increases the bonding strength of the photovoltaic module on the metal composite plate, and makes the system safer.

Description

Technical Field

[0001] The present disclosure relates to the technical field of photovoltaic modules, and in particular to a roof construction method and an installation structure of a photovoltaic module. Background Art

[0002] In the more than ten years since the beginning of the 21st century, energy shortages and environmental degradation have become increasingly prominent. Developing renewable energy to replace traditional energy is the only way to solve the above problems. Due to its huge reserves, clean use, and wide distribution, solar energy has become the most popular renewable energy in recent years. Building integrated photovoltaic (BIPV) technology is a technology that integrates solar power generation (photovoltaic) products into buildings. The roof of an industrial plant is generally a corrugated metal sheet structure. The assembled BIPV product combines the roof corrugated sheet with the photovoltaic module to make it a roof system that can generate electricity. In this system, the connection between the photovoltaic module and the corrugated sheet is through the bonding of structural adhesive.

[0003] In order to improve the waterproof ability of the metal roofing system, the corrugated metal sheet can use a film-coated board composed of waterproof membrane and metal plate. The overlap position of the two film-coated boards in the roofing system is welded by hot air to make the metal plate a whole to improve the waterproof ability of the system. The film-coated board is composited by bonding the waterproof membrane and the metal plate with adhesive. The waterproof membrane, especially the TPO membrane, has weak molecular polarity and low surface energy. It is difficult to bond photovoltaic modules to it by gluing, so that the bonding strength of photovoltaic modules on the roof is very low, affecting the application of the modules on the metal roof and the structural safety of the system. Summary of the invention

[0004] The purpose of the present disclosure is to provide a roof construction method and installation structure for photovoltaic modules. The construction method effectively increases the bonding force between the waterproof layer and the adhesive layer by forming a dielectric material layer between the waterproof layer and the adhesive layer, increases the bonding strength of the photovoltaic module on the metal composite plate, and makes the system safer.

[0005] In order to achieve the above-mentioned purpose, the first aspect of the present disclosure provides a roof construction method for photovoltaic modules, the construction method comprising: installing a waterproof layer on the roof, applying an adhesive layer on the waterproof layer, and installing the photovoltaic module on the adhesive layer; wherein a dielectric material layer is further included between the waterproof layer and the adhesive layer, the dielectric material layer comprises modified polyolefin and a coupling agent, and the waterproof layer comprises polyolefin.

[0006] Optionally, the adhesive layer is formed on the dielectric material layer, and the dielectric material layer includes a primer layer or a tackifier layer; the primer layer is formed by: coating a primer on the position of the waterproof layer where the adhesive layer needs to be applied, and the coating method includes one or more of brushing, spraying and rolling; the tackifier layer is formed by: welding the tackifier on the position of the waterproof layer where the adhesive layer needs to be applied using a hot air welding process, and the welding temperature is 150 to 300°C, preferably 150 to 220°C, and the time is 10 to 60s, preferably 10 to 30s.

[0007] Optionally, the weight average molecular weight of the modified polyolefin is 10,000 to 100,000; the modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin; preferably maleic anhydride grafted modified polyolefin; the grafting rate of the maleic anhydride grafted modified polyolefin is 0.8 to 10%; the coupling agent includes one or more of aminosilane coupling agent, epoxysilane coupling agent and vinylsilane coupling agent.

[0008] Optionally, the primer and the tackifier each independently include one or more of a crosslinker, a catalyst and a softener; the crosslinker includes one or more of alkoxysilanes, silicates, acyloxysilanes and ketoxime silanes; the catalyst includes one or more of dialkyltin dihydroxy acid salts, dialkoxytitanium bis(β-diketone esters) and titanate diol ester β-diketone; the softener includes one or more of ethylene propylene rubber, styrene butadiene rubber, nitrile rubber and butadiene rubber.

[0009] Optionally, the primer further includes a solvent, and the solvent includes one or more of toluene, xylene, ethyl acetate, butyl acetate, ethanol and acetone.

[0010] Optionally, the primer includes the modified polyolefin, the coupling agent, the solvent, the cross-linking agent, the catalyst and the softener; relative to 100 parts by weight of the solvent, the content of the modified polyolefin in the primer is 25 to 40 parts by weight, the content of the coupling agent is 5 to 20 parts by weight, the content of the cross-linking agent is 1 to 10 parts by weight, the content of the catalyst is 0.5 to 3 parts by weight, and the content of the softener is 0.1 to 1 part by weight; the tackifier includes the modified polyolefin, the coupling agent, the cross-linking agent, the catalyst and the softener; relative to 100 parts by weight of the modified polyolefin, the content of the coupling agent in the tackifier is 10 to 30 parts by weight, the content of the cross-linking agent is 5 to 15 parts by weight, the content of the catalyst is 3 to 10 parts by weight, and the content of the softener is 1 to 5 parts by weight.

[0011] Optionally, the thickness of the primer layer is less than 1 mm, the thickness of the adhesion-promoting layer is 0.1-0.8 mm, and the shape of the adhesion-promoting layer includes one or more of strips, cylinders, blocks and irregular shapes, preferably strips.

[0012] Optionally, the thickness of the waterproof layer is 0.6 to 2 mm, and the waterproof layer includes a thermoplastic polyolefin waterproof membrane, and the polyolefin in the thermoplastic polyolefin waterproof membrane includes polyethylene and polypropylene; the thermoplastic polyolefin waterproof membrane also contains rubber, and the rubber includes ethylene propylene rubber; preferably, the thermoplastic polyolefin waterproof membrane is a TPO waterproof membrane; the thickness of the adhesive layer is 1 to 6 mm, and the adhesive layer includes one or more of silicone structural adhesive, polyurethane structural adhesive and epoxy structural adhesive.

[0013] Optionally, the surface of the waterproof layer includes a smooth surface and / or an embossed surface; when the surface of the waterproof layer is a smooth surface, the solvent content in the primer is 70 to 80 parts by weight; and / or, when the surface of the waterproof layer is an embossed surface, the solvent content in the primer is 81 to 90 parts by weight.

[0014] Optionally, the method further comprises installing a metal composite panel on the roof so that the waterproof layer covers the metal composite panel, wherein the color of the metal composite panel comprises white, and the photovoltaic module comprises a double-sided photovoltaic module.

[0015] A second aspect of the present disclosure provides a photovoltaic module roof installation structure obtained by using the construction method described in the first aspect of the present disclosure.

[0016] A third aspect of the present disclosure provides a photovoltaic module roof mounting structure, the mounting structure comprising a waterproof layer, a dielectric material layer, an adhesive layer and a photovoltaic module arranged in sequence; wherein the dielectric material layer comprises modified polyolefin and a coupling agent, and the waterproof layer comprises polyolefin.

[0017] Optionally, the weight average molecular weight of the modified polyolefin is 10,000 to 100,000; the modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin; preferably maleic anhydride grafted modified polyolefin, wherein the grafting rate of the maleic anhydride grafted modified polyolefin is 0.8 to 10%; the waterproof layer also includes rubber, and the rubber includes ethylene propylene rubber; preferably, the waterproof layer is a TPO waterproof membrane; the adhesive layer includes one or more of silicone structural adhesive, polyurethane structural adhesive and epoxy structural adhesive.

[0018] Optionally, the dielectric material layer includes a primer layer or an adhesion-enhancing layer, and the primer layer and the adhesion-enhancing layer each independently further include one or more of a crosslinking agent, a catalyst and a softener; preferably, the primer layer includes the modified polyolefin, the coupling agent, the crosslinking agent, the catalyst and the softener; based on the total weight of the primer layer, the content of the modified polyolefin in the primer layer is 55-80% by weight, the content of the coupling agent is 5-30% by weight, the content of the crosslinking agent is 3.5-15% by weight, the content of the catalyst is 0.5-5% by weight, and the content of the softener is 0.1-3% by weight; the adhesion-enhancing layer includes the modified polyolefin, the coupling agent, the crosslinking agent, the catalyst and the softener; based on the total weight of the adhesion-enhancing layer As a benchmark, the content of the modified polyolefin in the adhesion-promoting layer is 64-80% by weight, the content of the coupling agent is 8-24% by weight, the content of the cross-linking agent is 4-12% by weight, the content of the catalyst is 2.4-8% by weight, and the content of the softener is 0.8-4% by weight; wherein the coupling agent includes one or more of an aminosilane coupling agent, an epoxysilane coupling agent and a vinylsilane coupling agent; the cross-linking agent includes one or more of an alkoxysilane, a silicate, an acyloxysilane and a ketoxime silane; the catalyst includes one or more of a dialkyltin dihydroxy acid salt, a dialkoxytitanium bis(β-diketone ester) and a titanate diol ester β-diketone; the softener includes one or more of ethylene-propylene rubber, styrene-butadiene rubber, nitrile rubber and butadiene rubber.

[0019] Optionally, the thickness of the primer layer is less than 1 mm, the thickness of the adhesion-promoting layer is 0.1 to 0.8 mm, the thickness of the waterproof layer is 0.6 to 2 mm, and the thickness of the adhesive layer is 1 to 6 mm.

[0020] Optionally, the mounting structure further comprises a metal composite plate, and the waterproof layer is covered on the metal composite plate; wherein the surface of the waterproof layer comprises a smooth surface and / or an embossed surface; the color of the metal composite plate comprises white, and the photovoltaic module comprises a double-sided photovoltaic module.

[0021] Through the above technical scheme, the roof construction method of the photovoltaic module provided by the present disclosure applies a dielectric material layer containing modified polyolefin between the waterproof layer and the adhesive layer, which is conducive to the modified polyolefin in the dielectric material layer diffusing into the waterproof layer, forming entanglement with the polyolefin molecular chain of the waterproof layer, and increasing the bonding force between the waterproof layer and the dielectric material layer; at the same time, the dielectric material layer also contains a coupling agent, which is conducive to the chemical reaction between the active group on the coupling agent and the hydroxyl group of the adhesive layer to form a stable chemical bond connection, enhance the connection strength between the dielectric material layer and the adhesive layer, so that the waterproof layer, the dielectric material layer and the adhesive layer form a whole with excellent bonding effect, thereby improving the bonding force between the adhesive layer and the waterproof layer, effectively improving the corrosion resistance of the metal composite plate and the waterproof ability of the system, improving the safety and stability of the system, and making the system have almost no attenuation of bonding strength after water bath aging. The waterproof layer and the adhesive layer of the photovoltaic module roof installation structure provided by the present disclosure have a high bonding strength, so that the photovoltaic module and the metal composite plate are effectively connected, and the overall structure is firm, the waterproof performance is good, and the safety performance is high, so as to realize photovoltaic building integration.

[0022] Other features and advantages of the present disclosure will be described in detail in the following detailed description. DETAILED DESCRIPTION

[0023] The specific embodiments of the present disclosure are described in detail below. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present disclosure, and are not used to limit the present disclosure.

[0024] A first aspect of the present disclosure provides a roof construction method for photovoltaic modules, the construction method comprising: installing a waterproof layer on the roof, applying an adhesive layer on the waterproof layer, and installing the photovoltaic module on the adhesive layer; wherein a dielectric material layer is further included between the waterproof layer and the adhesive layer, the dielectric material layer comprises modified polyolefin and a coupling agent, and the waterproof layer comprises polyolefin.

[0025] The roof construction method of the photovoltaic module provided by the present disclosure applies a dielectric material layer containing modified polyolefin between the waterproof layer and the adhesive layer, which is conducive to the modified polyolefin in the dielectric material layer diffusing into the waterproof layer and forming entanglement with the polyolefin molecular chain of the waterproof layer, thereby increasing the bonding force between the waterproof layer and the dielectric material layer; at the same time, the dielectric material layer also contains a coupling agent, which is conducive to the chemical reaction between the active groups on the coupling agent and the hydroxyl groups of the adhesive layer to form a stable chemical bond connection, thereby enhancing the connection strength between the dielectric material layer and the adhesive layer, so that the waterproof layer, the dielectric material layer and the adhesive layer form a whole with excellent bonding effect, thereby improving the bonding force between the adhesive layer and the waterproof layer, effectively improving the corrosion resistance of the metal composite plate and the waterproof ability of the system, improving the safety and stability of the system, and making the bonding strength of the system almost unchanged after water bath aging.

[0026] In one embodiment of the present disclosure, the adhesive layer is formed on the dielectric material layer, and the dielectric material layer includes a primer layer or an adhesion-enhancing layer; the primer layer is formed by: coating a primer on the position of the waterproof layer where the adhesive layer needs to be applied, and the coating method includes one or more of brushing, spraying and rolling. The coating method can be selected according to actual conditions, for example, the primer can be coated on the waterproof layer by manual brushing or rolling, or by machine spraying or brushing; the next step is performed after the solvent in the primer is completely evaporated, and the next step needs to be completed within 12 hours after the primer is formed to avoid the active ingredients in the primer being exposed to the air for a long time and oxidizing and failing, thereby weakening the adhesion-enhancing effect of the primer.

[0027] In another embodiment of the present disclosure, the formation method of the adhesion-enhancing layer includes: using a hot air welding process to weld the adhesion-enhancing agent to the position where the adhesive layer needs to be applied to the waterproof layer, the welding temperature is 150-300°C, preferably 150-220°C, and the time is 10-60s, preferably 10-30s. The hot air welding process can be selected according to actual conditions. In a specific embodiment, the hot air welding process can be carried out during the steel plate profiling process. In this process, the hot air welding device is integrated in the molding machine, and the adhesion-enhancing layer is directly welded to the position where the adhesive layer needs to be applied to the waterproof layer during the steel plate forming process, thereby achieving profiling and adhesion in one step. In another specific embodiment, the hot air welding process can be carried out after the steel plate is profiling, and the adhesion-enhancing layer is welded at the position where the adhesive layer needs to be applied to the waterproof layer by hot air welding equipment.

[0028] In the above embodiment, by applying a primer or a tackifier layer at the position where the waterproof layer contacts the adhesive layer, it is beneficial to increase the bonding force between the waterproof layer and the adhesive layer, and at the same time improve the surface energy of the waterproof layer, which is beneficial for the adhesive layer to wet the surface of the waterproof layer. Selecting the preferred hot air welding method is beneficial for the molecules of the waterproof layer to undergo a melting reaction, which is beneficial for the modified polyolefin molecular chains of the tackifier layer to further diffuse between the polyolefin molecular chains of the waterproof layer, and form entanglement with the polyolefin molecular chains in the waterproof layer, thereby improving the bonding force between the waterproof layer and the tackifier layer.

[0029] In one embodiment of the present disclosure, the weight average molecular weight of the modified polyolefin is 10,000 to 100,000; the modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin; in a preferred embodiment, the maleic anhydride grafted modified polyolefin can be, for example, maleic anhydride grafted modified polyethylene, maleic anhydride grafted modified polypropylene and maleic anhydride grafted modified propylene-ethylene copolymer, one or more; wherein the grafting rate of the maleic anhydride grafted modified polyolefin can be 0.8 to 10%. The acrylic acid grafted modified polyolefin can be, for example, one or more of acrylic acid grafted modified polyethylene, acrylic acid grafted modified polypropylene and acrylic acid grafted modified propylene-ethylene copolymer. The acetic acid grafted modified polyolefin can be, for example, one or more of acetic acid grafted modified polyethylene, acetic acid grafted modified polypropylene and acetic acid grafted modified propylene-ethylene copolymer. The silane grafted modified polyolefin can be, for example, one or more of silane grafted modified polyethylene, silane grafted modified polypropylene and silane grafted modified propylene-ethylene copolymer. In one embodiment, the modified polyolefin is maleic anhydride grafted modified polyolefin and / or acrylic acid grafted modified polyolefin. In the above embodiment, by selecting the preferred modified polyolefin, the modified polyolefin is further diffused into the waterproof layer, entangled with the polyolefin molecular chain in the waterproof layer, and the connection strength between the dielectric material layer and the waterproof layer is increased.

[0030] In one embodiment of the present disclosure, the coupling agent includes one or more of an aminosilane coupling agent, an epoxysilane coupling agent and a vinylsilane coupling agent; the aminosilane coupling agent is selected from one or more of γ-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane and γ-aminopropylmethyldiethoxysilane; the epoxysilane coupling agent is selected from one or more of γ-glycidoxypropyltrimethoxysilane, 3-(2,3-epoxypropyloxy)propyltriethoxysilane and 3-(2,3-epoxypropyloxy)propylmethyldimethoxysilane; the vinylsilane coupling agent is selected from one or more of vinyltriethoxysilane, vinyltrimethoxysilane and vinyltri(β-methoxyethoxy)silane. In the above embodiment, the preferred coupling agent is selected to facilitate the chemical reaction between the active groups on the coupling agent and the hydroxyl groups in the adhesive layer to form a stable chemical bond connection, thereby improving the bonding performance between the dielectric material layer and the adhesive layer, thereby improving the bonding force between the adhesive layer and the waterproof layer, and playing a role in improving the waterproof ability of the system.

[0031] In one embodiment of the present disclosure, the primer further comprises one or more of a cross-linking agent, a catalyst and a softener. In another embodiment, the tackifier further comprises one or more of a cross-linking agent, a catalyst and a softener.

[0032] In a preferred embodiment, the crosslinking agent includes one or more of alkoxysilane, silicate, acyloxysilane and ketoxime silane; the alkoxysilane is selected from one or more of n-octadecyltriethoxysilane, methyltrimethoxysilane and ethyltriethoxysilane; the silicate is selected from one or more of methyl orthosilicate, ethyl orthosilicate and tetrakis(2-methoxy-1-methylethyl) silicate; the acyloxysilane is selected from one or more of acryloxytrimethylsilane, 3-methacryloxypropylmethyldimethoxysilane and methacryloxypropyltriethoxysilane; the ketoxime silane is selected from one or more of methyltributylacetoximosilane, tetrabutylketoxime silane and tris(methylisobutylketoxime)methylsilane. In the above embodiment, the selection of a preferred crosslinking agent is conducive to improving the strength of the dielectric material layer.

[0033] In a preferred embodiment, the catalyst includes one or more of dialkyltin dihydroxy acid salt, dialkoxytitanium bis(β-diketone ester) and titanate diol ester β-diketone; the dialkyltin dihydroxy acid salt is selected from one or more of dibutyltin dilaurate, dibutyltin diacetate, dimethyltin dilaurate and dimethyltin diacetate. In the above embodiment, the preferred catalyst is selected to facilitate the chemical reaction between the coupling agent in the catalytic medium material layer and the modified polyolefin to form a cross-linked structure, thereby increasing the bonding force of the medium material layer.

[0034] In a preferred embodiment, the softener includes one or more of ethylene propylene rubber, styrene butadiene rubber, nitrile rubber and butadiene rubber. In the above embodiment, the preferred softener is selected to facilitate the modified polyolefin to diffuse into the waterproof layer more easily and form a good connection with the waterproof layer.

[0035] In one embodiment of the present disclosure, the primer further comprises a solvent, and the solvent comprises one or more of toluene, xylene, ethyl acetate, butyl acetate, ethanol and acetone. In the above embodiment, the selection of a preferred solvent is conducive to the swelling of the primer under the action of the solvent, so that the primer is better diffused into the waterproof layer and entangled with the polyolefin in the waterproof layer, thereby increasing the connection strength between the primer layer and the waterproof layer.

[0036] In one embodiment of the present disclosure, the primer includes the modified polyolefin, the coupling agent, the solvent, the cross-linking agent, the catalyst and the softener; relative to 100 parts by weight of the solvent, the content of the modified polyolefin in the primer is 25 to 40 parts by weight, the content of the coupling agent is 5 to 20 parts by weight, the content of the cross-linking agent is 1 to 10 parts by weight, the content of the catalyst is 0.5 to 3 parts by weight, and the content of the softener is 0.1 to 1 part by weight.

[0037] In another embodiment, the tackifier includes the modified polyolefin, the coupling agent, the crosslinking agent, the catalyst and the softener; relative to 100 parts by weight of the modified polyolefin, the content of the coupling agent in the tackifier is 10 to 30 parts by weight, the content of the crosslinking agent is 5 to 15 parts by weight, the content of the catalyst is 3 to 10 parts by weight, and the content of the softener is 1 to 5 parts by weight. In the above embodiment, by selecting the primer and tackifier with the preferred composition and ratio, it is beneficial to further improve the bonding force between the primer / tackifying layer and the adhesive layer and the waterproof layer, and improve the stability and safety of the system.

[0038] In one embodiment of the present disclosure, the thickness of the primer layer is less than 1 mm, the thickness of the adhesion-enhancing layer is 0.1 to 0.8 mm, and the shape of the adhesion-enhancing layer includes one or more of strips, cylinders, blocks and irregular shapes, preferably strips. In the above embodiment, by selecting the primer layer and adhesion-enhancing layer of preferred thickness, it is beneficial for the primer / adhesion-enhancing agent to be effectively combined with the waterproof layer.

[0039] In one embodiment of the present disclosure, the thickness of the waterproof layer is 0.6 to 2 mm, and the waterproof layer includes a thermoplastic polyolefin waterproof membrane, and the polyolefin in the thermoplastic polyolefin waterproof membrane includes polyethylene and polypropylene; in a preferred embodiment, the thermoplastic polyolefin waterproof membrane further includes rubber, and the rubber includes ethylene propylene rubber. In a specific embodiment, the thermoplastic polyolefin waterproof membrane is a TPO waterproof membrane; the thickness of the adhesive layer is 1 to 6 mm, and the adhesive layer includes one or more of silicone structural adhesive, polyurethane structural adhesive and epoxy structural adhesive. In the above embodiment, the thermoplastic polyolefin waterproof membrane is composed of multi-component polyolefin and rubber, and has the characteristics of low polarity, low surface energy, and difficult surface wetting; the selection of thermoplastic polyolefin waterproof membrane and adhesive layer of preferred thickness is conducive to the formation of a primer / adhesion-enhancing layer in the middle, thereby improving the bonding effect between the adhesive layer and the thermoplastic polyolefin waterproof membrane.

[0040] In one embodiment of the present disclosure, in order to reduce the reflection of light by the waterproof layer, the waterproof layer can be set to a variety of different surface morphologies, for example, it can be a smooth surface or an embossed surface, and the embossed surface is a surface morphology with different roughness and a pit structure manufactured by hot pressing on the thermoplastic polyolefin waterproof coil of the metal composite plate. In a specific embodiment, the surface of the waterproof layer is a smooth surface with a smaller roughness. At this time, the waterproof layer is more easily wetted by the primer, and the solvent content in the primer can be 70 to 80 parts by weight. In another specific embodiment, the surface of the waterproof layer is an embossed surface with a larger roughness. At this time, the waterproof layer is not easily wetted by the primer. At this time, the solvent content in the primer can be increased to increase the wetting effect. For example, the solvent content in the primer can be 81 to 90 parts by weight.

[0041] In one embodiment of the present disclosure, the method further comprises installing a metal composite panel on the roof so that the waterproof layer covers the metal composite panel, wherein the color of the metal composite panel comprises white, and the photovoltaic module comprises a double-sided photovoltaic module. In the above embodiment, the use of a white metal composite panel is conducive to the metal composite panel reflecting more light to the back of the double-sided photovoltaic module, thereby increasing the power generation of the double-sided photovoltaic module.

[0042] A second aspect of the present disclosure provides a photovoltaic module roof installation structure obtained by using the construction method described in the first aspect of the present disclosure.

[0043] A third aspect of the present disclosure provides a photovoltaic module roof mounting structure, the mounting structure comprising a waterproof layer, a dielectric material layer, an adhesive layer and a photovoltaic module arranged in sequence; wherein the dielectric material layer comprises modified polyolefin and a coupling agent, and the waterproof layer comprises polyolefin.

[0044] The waterproof layer and the adhesive layer of the photovoltaic module roof installation structure provided by the present invention have high bonding strength, so that the photovoltaic module and the metal composite panel are effectively connected, and the overall structure is firm, waterproof and safe, thus realizing photovoltaic building integration.

[0045] In one embodiment of the present disclosure, the weight average molecular weight of the modified polyolefin is 10,000 to 100,000; the modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin; preferably maleic anhydride grafted modified polyolefin, wherein the grafting rate of the maleic anhydride grafted modified polyolefin is 0.8 to 10%; the waterproof layer also includes rubber, and the rubber includes ethylene propylene rubber; in a preferred embodiment, the waterproof layer is a TPO waterproof membrane; the adhesive layer includes one or more of silicone structural adhesive, polyurethane structural adhesive and epoxy structural adhesive.

[0046] In one embodiment of the present disclosure, the dielectric material layer includes a primer layer or an adhesion-enhancing layer, and the primer layer and the adhesion-enhancing layer each independently further include one or more of a crosslinking agent, a catalyst and a softener; in a preferred embodiment, the primer layer includes a modified polyolefin, a coupling agent, a crosslinking agent, a catalyst and a softener; based on the total weight of the primer layer, the content of the modified polyolefin in the primer layer is 55 to 80% by weight, the content of the coupling agent is 5 to 30% by weight, the content of the crosslinking agent is 3.5 to 15% by weight, the content of the catalyst is 0.5 to 5% by weight, and the content of the softener is 0.1 to 3% by weight; in another preferred embodiment, the adhesion-enhancing layer includes a modified polyolefin, a coupling agent, a crosslinking agent, a catalyst and a softener; based on the total weight of the adhesion-enhancing layer Based on weight, the content of modified polyolefin in the adhesion-promoting layer is 64-80% by weight, the content of coupling agent is 8-24% by weight, the content of cross-linking agent is 4-12% by weight, the content of catalyst is 2.4-8% by weight, and the content of softener is 0.8-4% by weight; wherein the coupling agent includes one or more of aminosilane coupling agent, epoxysilane coupling agent and vinylsilane coupling agent; the cross-linking agent includes one or more of alkoxysilane, silicate, acyloxysilane and ketoxime silane; the catalyst includes one or more of dialkyltin dihydroxy acid salt, dialkoxytitanium bis (β-diketone ester) and titanate diol ester β-diketone; the softener includes one or more of ethylene propylene rubber, styrene butadiene rubber, nitrile rubber and butadiene rubber.

[0047] In one embodiment of the present disclosure, the thickness of the primer layer is less than 1 mm, the thickness of the adhesion-promoting layer is 0.1 to 0.8 mm, the thickness of the waterproof layer is 0.6 to 2 mm, and the thickness of the adhesive layer is 1 to 6 mm.

[0048] In one embodiment of the present disclosure, the mounting structure further comprises a metal composite plate, and the waterproof layer is covered on the metal composite plate; wherein the surface of the waterproof layer comprises a smooth surface and / or an embossed surface; the color of the metal composite plate comprises white, and the photovoltaic module comprises a double-sided photovoltaic module.

[0049] The present disclosure is further illustrated below by way of examples, but the present disclosure is not limited thereby.

[0050] In the following examples, unless otherwise specified, the raw materials used are commercially available products.

[0051] Example 1

[0052] A white metal composite panel is installed on the roof, a smooth TPO waterproofing membrane (waterproof layer, thickness of 0.8mm, the material of the TPO waterproofing membrane includes polyethylene, polypropylene and ethylene propylene rubber) is covered on the metal composite panel, and a primer is applied by mechanical spraying at the position where the adhesive layer needs to be applied on the waterproof layer, and after the solvent in the primer is completely evaporated, a primer layer is formed, and the thickness of the primer layer is less than 1mm; a silicone structural adhesive is applied on the primer layer to form an adhesive layer, and a double-sided photovoltaic module is installed on the adhesive layer to obtain a photovoltaic module roof installation structure 1; the photovoltaic module roof installation structure 1 includes a metal composite panel, a waterproof layer, a primer layer, an adhesive layer and a double-sided photovoltaic module arranged in sequence.

[0053] Among them, the content of toluene (solvent) in the primer is 80 parts by weight, the content of maleic anhydride grafted modified polyethylene (purchased from McLean, CAS is 9006-26-2, weight average molecular weight is 10000-50000, and grafting rate is 8%) is 30 parts by weight, the content of γ-aminopropyltrimethoxysilane (coupling agent) is 15 parts by weight, the content of methyltrimethoxysilane (cross-linking agent) is 5 parts by weight, the content of dibutyltin dilaurate (catalyst) is 2 parts by weight, and the content of ethylene-propylene rubber (softener) is 0.5 parts by weight. Based on the total weight of the primer layer of the mounting structure 1, the content of maleic anhydride grafted modified polyethylene in the primer layer of the mounting structure 1 is 57.1 weight %, the content of γ-aminopropyltrimethoxysilane is 28.6 weight %, the content of methyltrimethoxysilane is 9.5 weight %, the content of dibutyltin dilaurate is 3.8 weight %, and the content of ethylene propylene rubber is 1.0 weight %.

[0054] Example 2

[0055] The same as Example 1, the only difference is that: a white metal composite plate is installed on the roof, a waterproof layer is covered on the metal composite plate, a tackifier is welded on the waterproof layer by a hot air welding process, the welding position corresponds to the position where the waterproof layer needs to be applied with an adhesive layer, the welding temperature is 200°C, the time is 30s, and a strip-shaped tackifier strip is formed after welding, and the thickness is 0.6mm; a silicone structural adhesive is applied on the tackifier strip to form an adhesive layer, and the thickness is 2mm, and a double-sided photovoltaic module is installed on the adhesive layer to obtain a photovoltaic module roof installation structure 2;

[0056] Among them, the content of maleic anhydride grafted modified polyethylene in the tackifier is 90 parts by weight, the content of γ-aminopropyltrimethoxysilane (coupling agent) is 15 parts by weight, the content of methyltrimethoxysilane (crosslinking agent) is 10 parts by weight, the content of dibutyltin dilaurate (catalyst) is 5 parts by weight, and the content of ethylene-propylene rubber (softener) is 2 parts by weight. Based on the total weight of the tackifier layer of the mounting structure 2, the content of maleic anhydride grafted modified polyethylene in the tackifier layer is 73.8% by weight, the content of γ-aminopropyltrimethoxysilane is 12.3% by weight, the content of methyltrimethoxysilane is 8.2% by weight, the content of dibutyltin dilaurate is 4.1% by weight, and the content of ethylene-propylene rubber is 1.6% by weight.

[0057] Example 3

[0058] The same as Example 1, the only difference is that: a primer is applied on the embossed TPO waterproofing coil, the content of the solvent in the primer is 72 parts by weight, the content of maleic anhydride grafted modified polyethylene is 10 parts by weight, the content of γ-aminopropyltrimethoxysilane (coupling agent) is 5 parts by weight, the content of methyltrimethoxysilane (crosslinking agent) is 2.5 parts by weight, the content of dibutyltin dilaurate (catalyst) is 2 parts by weight, and the content of ethylene-propylene rubber (softener) is 0.5 parts by weight, to obtain a photovoltaic module roof mounting structure 3. Based on the total weight of the primer layer of the mounting structure 3, the content of maleic anhydride grafted modified polyethylene in the primer layer of the mounting structure 3 is 50% by weight, the content of γ-aminopropyltrimethoxysilane is 25% by weight, the content of methyltrimethoxysilane is 12.5% ​​by weight, the content of dibutyltin dilaurate is 10% by weight, and the content of ethylene-propylene rubber is 2.5% by weight.

[0059] Example 4

[0060] The same as Example 1, the only difference is: a primer is coated on the embossed TPO waterproof membrane, the solvent content in the primer is 85 parts by weight, an adhesive layer and a double-sided photovoltaic module are applied on the formed primer layer to obtain a photovoltaic module roof mounting structure 4.

[0061] Example 5

[0062] The same as Example 1, except that: the content of toluene (solvent) in the primer layer is 60 parts by weight, the content of maleic anhydride grafted modified polyethylene is 32.5 parts by weight, the content of γ-aminopropyltrimethoxysilane (coupling agent) is 10 parts by weight, the content of methyltrimethoxysilane (crosslinking agent) is 10 parts by weight, the content of dibutyltin dilaurate (catalyst) is 3 parts by weight, and the content of ethylene-propylene rubber (softener) is 2 parts by weight, to obtain a photovoltaic module roof mounting structure 5. Based on the total weight of the primer layer of the mounting structure 5, the content of maleic anhydride grafted modified polyethylene in the primer layer of the mounting structure 5 is 56.5% by weight, the content of γ-aminopropyltrimethoxysilane is 17.4% by weight, the content of methyltrimethoxysilane is 17.4% by weight, the content of dibutyltin dilaurate is 5.2% by weight, and the content of ethylene-propylene rubber is 3.5% by weight.

[0063] Example 6

[0064] The same as Example 2, the only difference is that the content of maleic anhydride grafted modified polyethylene in the tackifier is 70 parts by weight, the content of γ-aminopropyltrimethoxysilane (coupling agent) is 15 parts by weight, the content of methyltrimethoxysilane (cross-linking agent) is 15 parts by weight, the content of dibutyltin dilaurate (catalyst) is 10 parts by weight, and the content of ethylene-propylene rubber (softener) is 3 parts by weight, to obtain a photovoltaic module roof mounting structure 6. Based on the total weight of the tackifying layer of the mounting structure 6, the content of maleic anhydride grafted modified polyethylene is 61.9% by weight, the content of γ-aminopropyltrimethoxysilane is 13.3% by weight, the content of methyltrimethoxysilane is 13.3% by weight, the content of dibutyltin dilaurate is 8.8% by weight, and the content of ethylene-propylene rubber is 2.7% by weight.

[0065] Example 7

[0066] The same as Example 2, the only difference is that the welding temperature is 350° C., the time is 30 seconds, and the photovoltaic module roof mounting structure 7 is obtained.

[0067] Comparative Example 1

[0068] The same as Example 1, except that the maleic anhydride grafted modified polyethylene in the primer is replaced with the same weight of unmodified polyethylene (purchased from Maclean, CAS 9002-88-4, weight average molecular weight of 10000-50000), to obtain Comparative Structure 1.

[0069] Comparative Example 2

[0070] The same as Example 2, except that the maleic anhydride grafted modified polyethylene in the tackifier is replaced with the same weight of unmodified polyethylene (purchased from Maclean, CAS 9002-88-4, weight average molecular weight of 10000-50000), to obtain Comparative Structure 2.

[0071] Comparative Example 3

[0072] The same as Example 1, the only difference is that the surface of the TPO waterproof membrane is smooth, no primer or adhesion layer is applied thereon, and the silicone structural adhesive is directly applied on the TPO waterproof membrane to obtain a comparative structure 3.

[0073] Comparative Example 4

[0074] The same as Example 1, the only difference is that the surface of the TPO waterproof membrane is an embossed surface, no primer or adhesion layer is applied thereon, and the silicone structural adhesive is directly applied to the TPO waterproof membrane to obtain a comparative structure 4.

[0075] Test Case

[0076] The photovoltaic module roof mounting structures prepared in Examples 1 to 7 and the comparative structures prepared in Comparative Examples 1 to 4 were subjected to bonding strength tests, and their initial bonding strength and bonding strength after water bath aging were tested by a universal tensile machine, respectively, and the test standard was GB / T16776-2005; the water bath aging conditions were a temperature of 55°C and immersion in a water bath for 7 days; each group of tests included 5 parallel samples, and the final test results were the average of the 5 data. The test results are as follows:

[0077]

[0078]

[0079] From the above data, it can be seen that the bonding strength between the adhesive layer and the waterproof layer of the mounting structure obtained by Examples 1 to 7 using the construction method of the present disclosure is high, and the bonding strength is almost not attenuated after water bath aging; Comparative Examples 1 to 4 do not use the construction method of the present disclosure, and the bonding strength between the adhesive layer and the waterproof layer of the comparative structure obtained is weak, and cannot be used after water bath aging. Therefore, the construction method provided by Examples 1 to 7 of the present disclosure is better than that of Comparative Examples 1 to 4.

[0080] The preferred embodiments of the present disclosure are described in detail above; however, the present disclosure is not limited to the specific details in the above embodiments. Within the technical concept of the present disclosure, a variety of simple modifications can be made to the technical solution of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0081] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present disclosure will not further describe various possible combinations.

[0082] In addition, various embodiments of the present disclosure may be arbitrarily combined, and as long as they do not violate the concept of the present disclosure, they should also be regarded as the contents disclosed by the present disclosure.

Claims

1. A roof construction method for photovoltaic modules, characterized in that: The construction method comprises: installing a waterproof layer on a roof, applying an adhesive layer on the waterproof layer, and installing a photovoltaic module on the adhesive layer; wherein a dielectric material layer is further provided between the waterproof layer and the adhesive layer, the dielectric material layer comprises a modified polyolefin and a coupling agent, and the coupling agent comprises one or more of an aminosilane coupling agent, an epoxysilane coupling agent, and a vinylsilane coupling agent; the waterproof layer comprises polyolefin; the adhesive layer comprises a silicone structural adhesive; the dielectric material layer comprises a primer layer or an adhesion-enhancing layer; The formation method of the primer layer comprises: applying a primer to the position of the waterproof layer where the adhesive layer needs to be applied; the primer comprises the modified polyolefin, the coupling agent, a solvent, a cross-linking agent, a catalyst and a softener; relative to 100 parts by weight of the solvent, the content of the modified polyolefin in the primer is 25 to 40 parts by weight, the content of the coupling agent is 5 to 20 parts by weight, the content of the cross-linking agent is 1 to 10 parts by weight, the content of the catalyst is 0.5 to 3 parts by weight, and the content of the softener is 0.1 to 1 part by weight; The method for forming the adhesion layer includes: using a hot air welding process to weld the adhesion promoter at the position of the waterproof layer where the adhesive layer needs to be applied, and the welding temperature is 150-300° C.; The tackifier comprises the modified polyolefin, the coupling agent, the cross-linking agent, the catalyst and the softener; relative to 100 parts by weight of the modified polyolefin, the content of the coupling agent in the tackifier is 10 to 30 parts by weight, the content of the cross-linking agent is 5 to 15 parts by weight, the content of the catalyst is 3 to 10 parts by weight, and the content of the softener is 1 to 5 parts by weight.

2. The construction method according to claim 1, characterized in that: The adhesive layer is formed on the dielectric material layer, and the coating method includes one or more of brushing, spraying and rolling; The welding temperature is 150-220° C. and the welding time is 10-60 seconds.

3. The construction method according to claim 2, characterized in that: The welding time is 10 to 30 seconds.

4. The construction method according to claim 1, characterized in that: The weight average molecular weight of the modified polyolefin is 10,000 to 100,000; The modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin.

5. The construction method according to claim 4, characterized in that: The modified polyolefin is maleic anhydride grafted modified polyolefin; the grafting rate of the maleic anhydride grafted modified polyolefin is 0.8-10%.

6. The construction method according to claim 1, characterized in that: The crosslinking agent includes one or more of alkoxysilane, silicate, acyloxysilane and ketoxime silane; the catalyst includes one or more of dialkyltin dihydroxy acid salt, dialkoxytitanium bis (β-diketone ester) and titanate diol ester β-diketone; the softener includes one or more of ethylene propylene rubber, styrene butadiene rubber, nitrile rubber and butadiene rubber.

7. The construction method according to claim 1, characterized in that: The solvent includes one or more of toluene, xylene, ethyl acetate, butyl acetate, ethanol and acetone.

8. The construction method according to claim 1, characterized in that: The thickness of the primer layer is less than 1 mm, the thickness of the adhesion-promoting layer is 0.1-0.8 mm, and the shape of the adhesion-promoting layer includes one or more of strip, cylindrical, square and irregular shapes.

9. The construction method according to claim 8, characterized in that: The adhesion-promoting layer is in the shape of strips.

10. The construction method according to claim 1, characterized in that: The thickness of the waterproof layer is 0.6-2 mm, and the waterproof layer comprises a thermoplastic polyolefin waterproof roll, wherein the polyolefin in the thermoplastic polyolefin waterproof roll comprises polyethylene and polypropylene; the thermoplastic polyolefin waterproof roll also comprises rubber, wherein the rubber comprises ethylene propylene rubber; The thickness of the adhesive layer is 1 to 6 mm.

11. The construction method according to claim 10, characterized in that: The thermoplastic polyolefin waterproof membrane is a TPO waterproof membrane.

12. The construction method according to claim 10, characterized in that: The surface of the waterproof layer includes a smooth surface and / or an embossed surface; when the surface of the waterproof layer is a smooth surface, the solvent content in the primer is 70 to 80 parts by weight; and / or, When the surface of the waterproof layer is an embossed surface, the solvent content in the primer is 81 to 90 parts by weight.

13. The construction method according to claim 1, characterized in that: The method further comprises installing a metal composite panel on the roof so that the waterproof layer covers the metal composite panel, wherein the color of the metal composite panel comprises white, and the photovoltaic module comprises a double-sided photovoltaic module.

14. A photovoltaic module roof mounting structure obtained by the construction method described in any one of claims 1 to 13.

15. A photovoltaic module roof installation structure, characterized in that: The mounting structure comprises a waterproof layer, a dielectric material layer, an adhesive layer and a photovoltaic module arranged in sequence; wherein the dielectric material layer comprises a modified polyolefin and a coupling agent, and the coupling agent comprises one or more of an aminosilane coupling agent, an epoxysilane coupling agent and a vinylsilane coupling agent; the waterproof layer comprises polyolefin; the adhesive layer comprises a silicone structural adhesive; and the dielectric material layer comprises a primer layer or an adhesion-enhancing layer; The primer layer comprises the modified polyolefin, the coupling agent, the crosslinking agent, the catalyst and the softener; based on the total weight of the primer layer, the content of the modified polyolefin in the primer layer is 55-80% by weight, the content of the coupling agent is 5-30% by weight, the content of the crosslinking agent is 3.5-15% by weight, the content of the catalyst is 0.5-5% by weight, and the content of the softener is 0.1-3% by weight; The adhesion-promoting layer comprises the modified polyolefin, the coupling agent, the cross-linking agent, the catalyst and the softener; based on the total weight of the adhesion-promoting layer, the content of the modified polyolefin in the adhesion-promoting layer is 64-80 weight %, the content of the coupling agent is 8-24 weight %, the content of the cross-linking agent is 4-12 weight %, the content of the catalyst is 2.4-8 weight %, and the content of the softener is 0.8-4 weight %.

16. The mounting structure according to claim 15, characterized in that: The weight average molecular weight of the modified polyolefin is 10,000 to 100,000; the modified polyolefin includes one or more of maleic anhydride grafted modified polyolefin, acrylic acid grafted modified polyolefin, acetic acid grafted modified polyolefin and silane grafted modified polyolefin; The waterproof layer also includes rubber, and the rubber includes ethylene propylene rubber.

17. The mounting structure according to claim 16, characterized in that: The modified polyolefin is maleic anhydride grafted modified polyolefin, wherein the grafting rate of the maleic anhydride grafted modified polyolefin is 0.8-10%; and the waterproof layer is a TPO waterproof coiled material.

18. The mounting structure according to claim 15, characterized in that: The crosslinking agent includes one or more of alkoxysilane, silicate, acyloxysilane and ketoxime silane; the catalyst includes one or more of dialkyltin dihydroxy acid salt, dialkoxytitanium bis (β-diketone ester) and titanate diol ester β-diketone; the softener includes one or more of ethylene propylene rubber, styrene butadiene rubber, nitrile rubber and butadiene rubber.

19. The mounting structure according to claim 15, characterized in that: The thickness of the primer layer is less than 1 mm, the thickness of the adhesion-promoting layer is 0.1 to 0.8 mm, the thickness of the waterproof layer is 0.6 to 2 mm, and the thickness of the adhesive layer is 1 to 6 mm.

20. The mounting structure according to claim 15, characterized in that: The mounting structure further comprises a metal composite plate, and the waterproof layer is covered on the metal composite plate; Wherein, the surface of the waterproof layer includes a smooth surface and / or an embossed surface; the color of the metal composite plate includes white; and the photovoltaic module includes a double-sided photovoltaic module.

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