Composite fiber reinforced plate for photovoltaic panel, preparation method of composite fiber reinforced plate and light flexible photovoltaic panel

Abstract

The invention relates to the technical field of photovoltaic panels, and discloses a composite fiber reinforced panel for a photovoltaic panel, a preparation method of the composite fiber reinforced panel and a light flexible photovoltaic panel. The composite fiber reinforced plate comprises reinforced fiber cloth and a resin infiltrating material which is cured and formed after the reinforced fiber cloth is infiltrated; the resin infiltrating material comprises ceramic powder, unsaturated polyester resin, an initiator and an accelerant according to a specific mass ratio; the ceramic powder is aluminum oxide ceramic powder or silicon nitride ceramic powder, or mixed powder of aluminum oxide ceramic powder and titanium dioxide ceramic powder; the reinforced fiber cloth is polyimide fiber cloth or glass fiber cloth; the gram weight of the reinforced fiber cloth is 50-500g / m < 2 >, and the reinforced fiber cloth is laid in a single layer or multiple layers. The composite fiber reinforced plate has good scratch resistance, bending strength, dry heat yellowing resistance and high temperature resistance, also has the advantages of flexibility, light weight and difficulty in warping, ensures stable operation of the composite fiber reinforced plate in an extreme outdoor environment for a long time, and is suitable for a high-quality light flexible photovoltaic panel.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic panels, and in particular to a composite fiber reinforced panel for photovoltaic panels, a preparation method thereof, and a lightweight flexible photovoltaic panel. Background Art

[0002] In recent years, with the vigorous development of distributed photovoltaic power stations, the arrangement and application of photovoltaic modules on roofs of buildings with limited load-bearing capacity has gradually become the focus of promoting green energy. In this application context, lightweight photovoltaic modules are used. Lightweight photovoltaic modules usually use lightweight photovoltaic panels to replace the photovoltaic glass used in traditional photovoltaic modules as photovoltaic front panels and / or photovoltaic back panels to reduce the overall weight of photovoltaic modules, thereby facilitating the transportation, handling, installation and use of photovoltaic modules.

[0003] The existing lightweight photovoltaic panels, as shown in the publication number CN118254439A, have a light flame-retardant photovoltaic backplane whose upper surface layer is a thermosetting or thermoplastic composite material with thermal conductivity and fireproofing properties. The thermosetting or thermoplastic composite material with thermal conductivity and fireproofing properties includes the following components: 15-20 parts of thermal conductive fireproofing filler, 20-30 parts of randomly oriented long fibers, and 50-70 parts of thermosetting or thermoplastic resins; in this way, through fiber reinforcement, the lightweight photovoltaic backplane has the advantages of both lightness and high strength to meet the performance requirements of light photovoltaic modules in outdoor use, such as wind load resistance and snow load resistance. However, in the existing lightweight photovoltaic backplane, the thermosetting or thermoplastic composite materials used in the upper and lower surface layers are difficult to have good scratch resistance, bending strength, dry heat yellowing resistance, high temperature resistance, and not easy to warp, so it is difficult to promote and apply to high-quality lightweight and flexible photovoltaic panels. Summary of the invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide a composite fiber reinforced board for photovoltaic panels and a preparation method thereof, and a lightweight flexible photovoltaic panel.

[0005] Based on this, the present invention discloses a composite fiber reinforced board for photovoltaic panels, comprising: a reinforcing fiber cloth and a resin impregnating material for impregnating the reinforcing fiber cloth and then curing and forming;

[0006] The resin impregnation material comprises the following raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 5-10:90:2-1:0.6;

[0007] Wherein, the ceramic powder is alumina ceramic powder or silicon nitride ceramic powder, or a mixed powder formed by alumina ceramic powder and titanium dioxide ceramic powder;

[0008] Wherein, the reinforcing fiber cloth is polyimide fiber cloth or glass fiber cloth; the gram weight of the reinforcing fiber cloth is 50-500g / m2 , the reinforced fiber cloth is laid in single or multiple layers.

[0009] Preferably, the weight of the reinforced fiber cloth is 100-120 g / m 2 , 3-4 layers are laid in total; or, the weight of the reinforced fiber cloth is 500g / m 2 , a total of 1 layer is laid.

[0010] Preferably, the unsaturated polyester resin is a fluorine-free unsaturated polyester resin, and the fluorine-free unsaturated polyester resin is a linear unsaturated polyester resin and / or a propylene oxide-modified unsaturated polyester resin;

[0011] The initiator is at least one of dibenzoyl peroxide, cyclohexanone peroxide, and methyl ethyl ketone peroxide;

[0012] The accelerator is at least one of cobalt cyclohexaneate, cobalt isooctanoate, dimethylaniline and diethylaniline.

[0013] Further preferably, the resin impregnation material comprises raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 9:90:2-1:0.6.

[0014] More preferably, the resin impregnation material comprises raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 9:90:2:0.6.

[0015] Further preferably, the accelerator is N,N-dimethylaniline, and the initiator is dibenzoyl peroxide; or, the accelerator is cobalt isooctanoate, and the initiator is methyl ethyl ketone peroxide.

[0016] Preferably, the composite fiber reinforced board has a thickness of 100-800 μm (preferably 300-600 μm).

[0017] The present invention also discloses a method for preparing a composite fiber reinforced board for a photovoltaic panel, comprising the following preparation steps:

[0018] S1. Mix ceramic powder and unsaturated polyester resin, grind them together to less than 10 μm, then add initiator and accelerator, stir evenly, and then remove bubbles in vacuum to obtain resin impregnation material;

[0019] S2. Fully impregnate the polyimide fiber cloth with the resin impregnation material, and cover the upper and lower surfaces of the impregnated polyimide fiber cloth with two layers of release film respectively, so that the upper release film, the impregnated polyimide fiber cloth and the lower release film are squeezed together by rollers to remove bubbles, and then heated and cured at a curing temperature of 80-180° C. and a curing time of 10-60 min (the curing temperature and curing time are specifically affected by factors such as the line speed of the production line and the length of the oven), and then cut.

[0020] Preferably, in step S2, the heating curing is preferably low-temperature slow curing, wherein the curing temperature is 80-90°C and the curing time is 40-60 minutes.

[0021] The present invention also discloses a lightweight flexible photovoltaic panel, comprising a silicone protective layer, a fiber reinforcement layer and an inner adhesive material layer for bonding a packaging film, which are laminated in sequence from the outside to the inside. The fiber reinforcement layer is a composite fiber reinforced board for photovoltaic panels described above in the present invention.

[0022] Compared with the prior art, the present invention has at least the following beneficial effects:

[0023] The composite fiber reinforced board for photovoltaic panels of the present invention is formed by curing after impregnating reinforcing fiber cloth with resin impregnating material. The resin impregnating material is prepared by combining ceramic powder, unsaturated polyester resin, initiator and accelerator in a mass ratio of 5-10:90:2-1:0.6, and the type, gram weight and number of laying layers of the reinforcing fiber cloth are optimized. A composite fiber reinforced board with good scratch resistance, bending strength, dry heat yellowing resistance and high temperature resistance can be obtained. The composite fiber reinforced board also has the advantages of flexibility, light weight, good flatness and not easy to warp, thereby ensuring the long-term stable operation of the composite fiber reinforced board in extreme outdoor environments, and is particularly suitable for application in high-quality lightweight flexible photovoltaic panels. DETAILED DESCRIPTION

[0024] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below in conjunction with specific implementation methods.

[0025] Example 1

[0026] A composite fiber reinforced plate for a photovoltaic panel in this embodiment includes: a polyimide fiber cloth and a resin impregnating material for impregnating the polyimide fiber cloth; the resin impregnating material includes: a ceramic powder, an unsaturated polyester resin, an initiator and a accelerator in a mass ratio of 9:90:1:0.6.

[0027] The ceramic powder is alumina, the unsaturated polyester is linear unsaturated polyester resin, the initiator is methyl ethyl ketone peroxide, and the accelerator is cobalt cyclohexaneate.

[0028] Among them, the weight of polyimide fiber cloth is 120g / m 2 , a total of 3 layers of polyimide fiber cloth are laid.

[0029] A method for preparing a composite fiber reinforced board for a photovoltaic panel in this embodiment includes the following preparation steps:

[0030] Step 1: Mix ceramic powder and unsaturated polyester resin, grind them together to less than 10 μm, then mix the ground ceramic powder and unsaturated polyester resin with an initiator and an accelerator, stir evenly, and then remove bubbles by vacuum to obtain a resin impregnation material.

[0031] Step 2: Use a coating machine to fully impregnate the polyimide fiber cloth with the resin impregnation material, and cover the upper and lower surfaces of the impregnated polyimide fiber cloth with two layers of release film, respectively. The upper release film, the impregnated polyimide fiber cloth and the lower release film are squeezed and defoamed by a steel roller to ensure that the thickness of the resin impregnation material, the speed of the two layers of release film and the impregnated polyimide fiber cloth match each other, and then enter the oven for heating and curing. The curing temperature is 150°C and the curing time is 20 minutes. Cut to obtain the composite fiber reinforced board for photovoltaic panels with a thickness of 400 μm in this embodiment.

[0032] Before using the composite fiber-reinforced board for photovoltaic panels, the upper and lower release films need to be removed.

[0033] A lightweight flexible photovoltaic panel of this embodiment includes a silicone protective layer, a fiber reinforcement layer, and an inner adhesive material layer for bonding the packaging film, which are laminated from the outside to the inside; the fiber reinforcement layer is a composite fiber reinforced board for photovoltaic panels prepared as described above in this embodiment. The lightweight flexible photovoltaic panel of this embodiment can be used as a photovoltaic front panel and / or photovoltaic back panel in a lightweight flexible photovoltaic module.

[0034] Example 2

[0035] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 1, and the difference between them and Example 1 is that:

[0036] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the ceramic powder used in the resin impregnation material is a mixed powder of aluminum oxide and titanium dioxide, and the mass ratio of the mixed powder is 5:4 to form a white composite fiber reinforced board for photovoltaic panels.

[0037] Example 3

[0038] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0039] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the weight of the polyimide fiber cloth is 100 g / m 2 A total of 4 layers of polyimide fiber cloth were laid, and the thickness of the obtained composite fiber reinforced board for photovoltaic panels was 600 μm.

[0040] Example 4

[0041] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0042] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the weight of the polyimide fiber cloth is 500 g / m 2 , a total of 1 layer of polyimide fiber cloth is laid, and the thickness of the obtained composite fiber reinforced board for photovoltaic panels is 600 μm.

[0043] Example 5

[0044] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0045] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the mass ratio of the ceramic powder, unsaturated polyester resin, initiator and accelerator used in the resin impregnation material is 9:90:2:0.6.

[0046] Example 6

[0047] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0048] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the polyimide fiber cloth is replaced by glass fiber cloth.

[0049] Example 7

[0050] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0051] In the method for preparing the composite fiber reinforced board for photovoltaic panels of this embodiment, the heating and curing conditions of step 2 are changed to: the curing temperature is 90° C. and the curing time is 40 min.

[0052] Example 8

[0053] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0054] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the accelerator in the resin impregnation material used is changed to cobalt isooctanoate.

[0055] Example 9

[0056] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel of this embodiment are all referred to in Example 2, and the difference between them and Example 2 is that:

[0057] In the composite fiber reinforced board for photovoltaic panels of this embodiment, the initiator in the resin impregnation material used is replaced with dibenzoyl peroxide, and the accelerator is replaced with N,N-dimethylaniline.

[0058] Comparative Example 1

[0059] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel in this comparative example are all referred to Example 2, and the difference between them and Example 2 is that:

[0060] In the composite fiber reinforced board for photovoltaic panels of this comparative example, no accelerant is added to the resin impregnation material used.

[0061] Comparative Example 2

[0062] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel in this comparative example are all referred to Example 2, and the difference between them and Example 2 is that:

[0063] In a composite fiber reinforced board for a photovoltaic panel in this comparative example, ceramic powder is not added to the resin impregnating material used, but is replaced by silicon dioxide matting powder.

[0064] Comparative Example 3

[0065] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel in this comparative example are all referred to Example 2, and the difference between them and Example 2 is that:

[0066] In a composite fiber reinforced board for photovoltaic panels of this comparative example, unsaturated polyester resin is not added to the resin impregnation material used, but is replaced by: a thermosetting epoxy resin containing more than two epoxy groups, and correspondingly, the initiator is replaced by: an organic amine initiator N,N-dimethylaniline.

[0067] Comparative Example 4

[0068] The composite fiber reinforced board for photovoltaic panels and its preparation method and the lightweight flexible photovoltaic panel in this comparative example are all referred to Example 2, and the difference between them and Example 2 is that:

[0069] In the composite fiber reinforced board for photovoltaic panels of this comparative example, unsaturated polyester resin is not added to the resin impregnation material, but is replaced by powdered polyester resin.

[0070] Comparative Example 5

[0071] A composite fiber reinforced board for photovoltaic panels and a preparation method thereof and a lightweight flexible photovoltaic panel in this comparative example are all referred to Example 1, and the difference between them and Example 1 is that:

[0072] In a composite fiber reinforced board for a photovoltaic panel of this comparative example, the mass ratio of the ceramic powder, unsaturated polyester resin, initiator and accelerator used in the resin impregnation material is 9:90:2:2.

[0073] Performance Testing

[0074] The performance tests were performed on the composite fiber reinforced boards for photovoltaic panels of Examples 1-9 and Comparative Examples 1-5, and the test results are shown in Table 1 below:

[0075] Table 1

[0076]

[0077]

[0078] The curing of unsaturated polyester resin is a process in which its linear macromolecules form a three-dimensional network through cross-linking. However, the curing process cannot consume all the active double bonds in the unsaturated polyester resin to achieve 100% curing degree, which means that it is difficult for unsaturated polyester resin to achieve complete curing. The reason is that in the later stage of the curing reaction, the viscosity of the system increases sharply, which hinders the molecular diffusion of the unsaturated polyester resin and thus affects the curing. Generally, it is considered that the curing is complete only when the material properties tend to be stable.

[0079] According to the data in Table 1, we can know that:

[0080] (1) As the number of layers of the polyimide fiber cloth increases (such as in Example 3) or the grammage of the polyimide fiber cloth increases (such as in Example 4), the bending strength of the composite fiber reinforced board for photovoltaic panels is significantly improved.

[0081] Properly increasing the content of the initiator (such as in Example 5) can improve the curing degree of the resin impregnation material, which can also improve the bending strength of the composite fiber reinforced board for photovoltaic panels. However, if the content of the initiator is too high, it is easy to cause the composite fiber reinforced board for photovoltaic panels to warp and deform.

[0082] Optimizing the curing conditions of the resin impregnation material and curing it slowly at low temperature (such as Example 7) can help achieve more uniform impregnation of the polyimide fiber cloth with the resin impregnation material, which can also help improve the bending strength of the composite fiber reinforced board for photovoltaic panels.

[0083] Compared with using cobalt cyclohexaneate as a promoter (such as Example 2), when the initiator is methyl ethyl ketone peroxide, using cobalt isooctanoate as a promoter (such as Example 8) is more helpful in improving the degree of curing of the resin impregnation material, and thus the bending strength of the composite fiber reinforced board for photovoltaic panels in Example 8 is slightly improved.

[0084] Compared with using cobalt cyclopentaneate as a promoter and methyl ethyl ketone peroxide as an initiator (such as Example 2), using N,N-dimethylaniline as a promoter and dibenzoyl peroxide as an initiator (such as Example 9) is more helpful to improve the degree of curing of the resin impregnation material, and thus the bending strength of the composite fiber reinforced board for photovoltaic panels in Example 9 is improved.

[0085] (2) If no accelerator is added to the resin impregnation material (such as in Comparative Example 1) or the amount of accelerator added to the resin impregnation material is too large (such as in Comparative Example 5), the degree of curing of the resin impregnation material is too low, and the scratch resistance, bending strength and dry heat yellowing resistance of the composite fiber reinforced board for photovoltaic panels obtained will be significantly reduced. Therefore, the amount of accelerator added to the resin impregnation material should not be too much, and the molar ratio of the accelerator to the initiator should be kept less than 1. Otherwise, the reaction rate of the accelerator and the primary free radical will be greater than the rate of curing initiated by the primary free radical, causing the curing of the resin impregnation material to become too slow, affecting its degree of curing. Adding too much accelerator cannot achieve the effect of accelerating the curing of the resin impregnation material, but will instead reduce the product performance.

[0086] If the unsaturated polyester resin in the resin impregnation material is not combined with ceramic powder, but is combined with silica matting powder (such as comparative example 2), the scratch resistance, bending strength and dry heat yellowing resistance of the composite fiber reinforced board for photovoltaic panels obtained will be reduced.

[0087] However, if the ceramic powder in the resin impregnation material is not combined with unsaturated polyester resin, but with epoxy resin instead (such as comparative example 3), the scratch resistance, bending strength and dry heat yellowing resistance of the composite fiber reinforced board for photovoltaic panels obtained will all decrease, especially its dry heat yellowing resistance will decrease significantly, and it will easily become white and yellow due to aging.

[0088] However, if the ceramic powder in the resin impregnation material is not combined with unsaturated polyester resin but with powdered polyester resin instead, the resulting composite fiber reinforced board for photovoltaic panels will warp and have an uneven surface, and the scratch resistance, bending strength and dry heat yellowing resistance of the composite fiber reinforced board for photovoltaic panels will all decrease.

[0089] Although the preferred embodiments of the present invention have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the embodiments of the present invention.

[0090] The technical solution provided by the present invention is introduced in detail above. Specific examples are used in this article to illustrate the principle and implementation mode of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core idea. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation mode and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A composite fiber reinforced board for photovoltaic panels, characterized in that: include: Reinforcing fiber cloth and a resin impregnating material used for impregnating the reinforcing fiber cloth and then curing and forming; The resin impregnation material comprises the following raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 5-10:90:2-1:0.6; Wherein, the ceramic powder is alumina ceramic powder or silicon nitride ceramic powder, or a mixed powder formed by alumina ceramic powder and titanium dioxide ceramic powder; Wherein, the reinforcing fiber cloth is polyimide fiber cloth or glass fiber cloth; the gram weight of the reinforcing fiber cloth is 50-500g / m 2 , the reinforced fiber cloth is laid in single or multiple layers.

2. A composite fiber reinforced board for photovoltaic panels according to claim 1, characterized in that: The gram weight of the reinforced fiber cloth is 100-120g / m 2 , 3-4 layers are laid in total; or, the weight of the reinforced fiber cloth is 500g / m 2 , a total of 1 layer is laid.

3. A composite fiber reinforced board for photovoltaic panels according to claim 1, characterized in that: The unsaturated polyester resin is a fluorine-free unsaturated polyester resin, and the fluorine-free unsaturated polyester resin is a linear unsaturated polyester resin and / or a propylene oxide-modified unsaturated polyester resin; The initiator is at least one of dibenzoyl peroxide, cyclohexanone peroxide, and methyl ethyl ketone peroxide; The accelerator is at least one of cobalt cyclohexaneate, cobalt isooctanoate, dimethylaniline and diethylaniline.

4. A composite fiber reinforced board for photovoltaic panels according to any one of claims 1 to 3, characterized in that: The resin impregnation material comprises raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 9:90:2-1:0.

6.

5. The composite fiber reinforced board for photovoltaic panels according to claim 4, characterized in that: The resin impregnation material comprises raw materials in the following mass ratio: the mass ratio of ceramic powder, unsaturated polyester resin, initiator and accelerator is 9:90:2:0.

6.

6. A composite fiber reinforced board for photovoltaic panels according to any one of claims 1 to 3, characterized in that: The accelerator is N,N-dimethylaniline, and the initiator is dibenzoyl peroxide; or, the accelerator is cobalt isooctanoate, and the initiator is methyl ethyl ketone peroxide.

7. A composite fiber reinforced board for photovoltaic panels according to any one of claims 1 to 3, characterized in that: The thickness of the composite fiber reinforced board is 300-600 μm.

8. A method for preparing a composite fiber reinforced board for photovoltaic panels according to any one of claims 1 to 7, characterized in that: The method comprises the following preparation steps: S1. Mix ceramic powder and unsaturated polyester resin, grind them together to less than 10 μm, then add initiator and accelerator, stir evenly, and then remove bubbles in vacuum to obtain resin impregnation material; S2. Fully impregnate the polyimide fiber cloth with the resin impregnation material, and cover the upper and lower surfaces of the impregnated polyimide fiber cloth with two layers of release films respectively, so that the upper release film, the impregnated polyimide fiber cloth and the lower release film are squeezed together by rollers to remove bubbles, and then heat-cured at a curing temperature of 80-180° C. and a curing time of 10-60 min, and then cut.

9. The method for preparing a composite fiber reinforced board for photovoltaic panels according to claim 8, characterized in that: In step S2, the curing temperature is 80-90°C and the curing time is 40-60 minutes.

10. A lightweight flexible photovoltaic panel, comprising a silicone protective layer, a fiber reinforcement layer and an inner bonding material layer for bonding a packaging film, which are laminated in sequence from the outside to the inside, characterized in that: The fiber-reinforced layer is a composite fiber-reinforced board for a photovoltaic panel as described in any one of claims 1 to 7.

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