Modified butyl sealant as well as preparation method and application thereof

Abstract

The invention relates to a modified butyl sealant as well as a preparation method and application thereof. The modified butyl sealant comprises at least one butyl rubber layer and at least one fiber reinforced layer which are arranged in a stacked mode, and the at least one butyl rubber layer and the at least one fiber reinforced layer are alternately arranged in the thickness direction of the modified butyl sealant. By means of the mode that the at least one butyl rubber layer and the at least one fiber reinforcing layer are arranged in the stacked mode, the elasticity modulus of butyl rubber can be increased, the strength can be improved, the problem of cracking cannot occur under the condition that thermal cycling stress exists or under an aging test, and then the reliability of the assembly is improved.

Description

Technical Field

[0001] The present application relates to the field of butyl sealants, and in particular to a modified butyl sealant and a preparation method and application thereof. Background Art

[0002] With the development of high-efficiency battery module technology, new high-efficiency batteries such as heterojunction solar cells (HJT) and perovskite cells have attracted much attention due to their excellent photoelectric conversion efficiency. Due to its molecular structure, butyl sealant is currently recognized as the best polymer material with the best airtightness and watertightness, and is widely used in the packaging of photovoltaic modules that are sensitive to water vapor. For example, HJT battery modules are currently packaged using a combination of thermosetting film and butyl sealant, and perovskite battery modules are packaged using a combination of thermoplastic film and butyl sealant. However, the current butyl sealant used in battery modules is prone to failure during long-term aging, such as cracking of butyl sealant, which loses the high elasticity of butyl sealant and causes module failure. Summary of the invention

[0003] Based on this, some embodiments of the present application provide a modified butyl sealant, which is used in photovoltaic modules and can effectively improve the cracking problem that occurs during long-term aging and reduce the risk of module failure.

[0004] In addition, other embodiments of the present application also provide a preparation method and application of a modified butyl sealant.

[0005] A modified butyl sealant comprises: at least one butyl rubber layer and at least one fiber reinforcement layer which are stacked, wherein along the thickness direction of the modified butyl sealant, the at least one butyl rubber layer and the at least one fiber reinforcement layer are alternately arranged.

[0006] In some of the embodiments, n+1 layers of the butyl rubber layer and n layers of the fiber reinforced layer are included, n is an integer greater than or equal to 1, and along the thickness direction of the modified butyl sealant, the n+1 layers of the butyl rubber layer and the n layers of the fiber reinforced layer are alternately stacked.

[0007] In some of the embodiments, the ratio of the total thickness of the n+1 layers of the butyl rubber layer to the total thickness of the n layers of the fiber reinforced layer is 1:(1-3).

[0008] In some of the embodiments, the ratio of the total thickness of the n+1 layers of the butyl rubber layer to the total thickness of the n layers of the fiber reinforced layer is 1:(1-2).

[0009] In some of the embodiments, each of the butyl rubber layers independently comprises, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene and 200 to 400 parts of inorganic inert filler.

[0010] In some of the embodiments, each of the butyl rubber layers independently comprises: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an antioxidant.

[0011] In some embodiments, each of the butyl rubber layers independently satisfies one or more of the following conditions:

[0012] (1) The inorganic inert filler includes one or more of silicon dioxide, carbon black, talc, kaolin and calcium carbonate;

[0013] (2) The desiccant includes one or more of molecular sieve, calcium oxide, calcium chloride, magnesium sulfate and activated alumina;

[0014] (3) The tackifying resin includes one or more of rosin resin, epoxy resin, polyterpene resin and phenolic resin;

[0015] (4) The antioxidant includes one or more of benzophenone, triazines, triazoles, hindered amines, salicylates and benzophenones.

[0016] In some embodiments, the material of each fiber-reinforced layer independently includes one or more of glass fiber, carbon fiber and polyester fiber.

[0017] A modified butyl sealant comprises a first butyl rubber layer, wherein the first butyl rubber layer is filled with reinforcing fibers.

[0018] In some of the embodiments, the first butyl rubber layer includes, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene, 200 to 400 parts of inorganic inert filler and 20 to 60 parts of reinforcing fiber.

[0019] In some embodiments, the first butyl rubber layer further includes: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an antioxidant.

[0020] In some of the embodiments, the modified butyl sealant further comprises a second butyl rubber layer disposed on at least one side of the first butyl rubber layer, and the second butyl rubber layer does not contain reinforcing fibers.

[0021] In some embodiments, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.5).

[0022] In some embodiments, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.2).

[0023] In some embodiments, the reinforcing fiber includes one or more of glass fiber, carbon fiber and polyester fiber.

[0024] A method for preparing a modified butyl sealant comprises the following steps:

[0025] Forming at least one butyl rubber layer and at least one fiber reinforcement layer stacked to prepare a modified butyl sealant, wherein the at least one butyl rubber layer and the at least one fiber reinforcement layer are alternately arranged along the thickness direction of the modified butyl sealant; or,

[0026] A butyl rubber layer filled with reinforcing fibers is formed to prepare a modified butyl sealant.

[0027] The modified butyl sealant mentioned above is used in the preparation of photovoltaic modules.

[0028] A photovoltaic component comprises the modified butyl sealant or the modified butyl sealant prepared by the preparation method.

[0029] The present application has found that battery components such as perovskite battery components use a combination of thermoplastic film and butyl adhesive to achieve water-blocking packaging, but the thermoplastic film itself has a low modulus and is prone to creep, shrinkage and other problems in high temperature environments. Traditional butyl sealants are thermoplastic sealants with poor cohesion and insufficient strength. They crack during long-term aging, which in turn causes the perovskite film layer to fall off and the component to fail. Based on this, some embodiments of the present application provide a modified butyl sealant, which can increase the elastic modulus of the butyl sealant and improve its strength by stacking at least one butyl layer and at least one fiber-reinforced layer. There will be no cracking problems under conditions of cold and hot cycle stress or during aging, thereby improving the reliability of the component. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0031] Figure 1 A schematic diagram of the structure of a modified butyl sealant provided in some embodiments of the present application;

[0032] Figure 2 A schematic diagram of the structure of a modified butyl sealant provided in some other embodiments of the present application;

[0033] Figure 3A schematic diagram of the structure of a modified butyl sealant provided in some embodiments of the present application;

[0034] Figure 4 A schematic diagram of the structure of a modified butyl sealant provided in some embodiments of the present application;

[0035] Figure 5 A schematic diagram of the structure of a modified butyl sealant provided in some embodiments of the present application;

[0036] Figure 6 A schematic diagram showing that the butyl sealant of Comparative Example 1 is applied to a photovoltaic module and cracking of the photovoltaic module occurs after a TC aging test;

[0037] Figure 7 This is a schematic diagram showing that the butyl sealant of Example 1 is applied to a photovoltaic module, and the photovoltaic module has no cracks after the TC aging test, and the photovoltaic module has not failed. DETAILED DESCRIPTION

[0038] In order to facilitate the understanding of the present application, the present application will be described more comprehensively below in conjunction with the specific embodiments. The preferred embodiments of the present application are provided in the specific embodiments. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present application more thorough and comprehensive.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which the present application belongs. The terms used herein in the specification of the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0040] Unless otherwise specified or there is a contradiction, the terms and phrases used in this application have the following meanings:

[0041] In this application, "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the features.

[0042] In the description of the present application, “plurality” means at least two, for example, two, three, etc., unless otherwise clearly and specifically defined.

[0043] In this application, "one or several" refers to any one, any two or more of the listed items. Among them, "several" refers to any two or more of the listed items.

[0044] In this application, the percentage concentration involved, unless otherwise specified, refers to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of the component.

[0045] In this document, "further", "further", "particularly", "for example", "such as", "example", "for example", etc. are used for descriptive purposes, indicating that the previous and subsequent technical solutions are related in terms of the content covered, but should not be understood as a limitation on the previous technical solution, nor can it be understood as a limitation on the protection scope of this document. In this document, unless otherwise specified, A (such as B) means that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0046] Herein, "optionally", "optional", and "optional" mean optional, that is, any one of the two parallel schemes of "yes" or "no". If multiple "optional" items appear in a technical solution, unless otherwise specified and there is no contradiction or mutual restriction, each "optional" item is independent of each other. In this application, descriptions such as "optionally contain", "optionally include", etc. mean "contain or not contain". "Optional component X" means that component X exists or does not exist, or means that component X is contained or not contained.

[0047] When a numerical range is disclosed in this application, the above range is considered to be continuous and includes the minimum and maximum values ​​of the range, as well as every value between such minimum and maximum values. Further, when a range refers to an integer, every integer between the minimum and maximum values ​​of the range is included. In addition, when multiple ranges are provided to describe features or characteristics, the ranges can be combined. In other words, unless otherwise indicated, all ranges disclosed in this application should be understood to include any and all subranges included therein.

[0048] In the present application, the technical features described in an open manner include closed technical solutions composed of the listed features, and also include open technical solutions containing the listed features.

[0049] The terms "including" and "having" and any variations thereof in the embodiments of the present application are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or components that are inherent to these processes, methods, products, or devices.

[0050] Reference to "embodiments" in this application means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described in this application may be combined with other embodiments.

[0051] As described in the background technology, some battery components such as perovskite batteries are more sensitive to water vapor, and the battery packaging protection requirements are increased. - Ions are reducing and will react chemically with oxidizing substances to destroy the film layer. Therefore, thermoplastic film (TPO) is often used for perovskite encapsulation. In order to improve its water barrier, butyl sealant is used together. However, traditional butyl sealant is prone to cracking during aging, which leads to the failure of battery components. Based on this, the present application provides a modified butyl sealant and a preparation method thereof.

[0052] In a first aspect, the present application provides a modified butyl sealant, comprising: a first butyl rubber layer, wherein the first butyl rubber layer is filled with reinforcing fibers.

[0053] The present application has found that battery components such as perovskite battery components use a combination of thermoplastic film and butyl adhesive to achieve water-blocking encapsulation, but the thermoplastic film itself has a low modulus and is prone to creep, shrinkage and other problems in high temperature environments. Traditional butyl sealants are thermoplastic sealants with poor cohesion and insufficient strength. They crack during long-term aging, which in turn causes the perovskite film layer to fall off and the components to fail. Based on this, some embodiments of the present application provide a modified butyl sealant, which can increase the elastic modulus of the butyl adhesive and improve its strength by filling reinforcing fibers in the butyl adhesive layer. It will not crack under conditions of cold and hot cycle stress or aging tests, thereby improving the reliability of the components.

[0054] In addition, due to the poor cohesion of butyl sealant, problems such as glue penetration may occur during the assembly processing. Under high temperature conditions outdoors, if the butyl sealant is not strong enough, the internal packaging film may cause problems such as high-temperature flow driving the battery cells to shift, and short circuits caused by paralleling. In some embodiments of the present application, by filling reinforcing fibers in the butyl sealant layer, the strength of the butyl sealant is improved, and the risk of high-temperature flow of the internal packaging film driving the battery cells to shift, and short circuits caused by paralleling is reduced.

[0055] The butyl rubber layer is a polymer of butyl rubber matrix and polyisoolefin, and is a thermoplastic material with coupling agent, antioxidant, inorganic filler, etc. added to achieve the bonding function. It is a non-cross-linked system.

[0056] In some embodiments, the first butyl rubber layer includes, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene (PIB), 200 to 400 parts of inorganic inert filler, and 20 to 60 parts of reinforcing fiber.

[0057] Optionally, the first butyl rubber layer further includes: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an anti-aging agent.

[0058] Butyl rubber is synthesized from isobutylene and a small amount of isoprene. Exemplarily, the mass fraction of butyl rubber can be, but is not limited to, 150 parts, 160 parts, 180 parts, 200 parts, 220 parts, 240 parts, 250 parts, 260 parts, 280 parts, 300 parts, or a range consisting of any two of these values.

[0059] Polyisobutylene is a polymer obtained by cationic polymerization of isobutylene, and is a typical saturated linear polymer. For example, the mass fraction of polyisobutylene can be, but is not limited to, 30 parts, 40 parts, 50 parts, 60 parts, 70 parts, 80 parts, 90 parts, 100 parts, or a range consisting of any two of these values.

[0060] In some embodiments, the inorganic inert filler includes one or more of silicon dioxide, carbon black, talc, kaolin and calcium carbonate. For example, the mass fraction of the inorganic inert filler can be, but is not limited to, 200 parts, 220 parts, 250 parts, 280 parts, 300 parts, 320 parts, 350 parts, 380 parts, 400 parts or a range consisting of any two of these values.

[0061] In some embodiments, the desiccant includes one or more of molecular sieve, calcium oxide, calcium chloride, magnesium sulfate and activated alumina. Among them, the molecular sieve includes but is not limited to 3A type molecular sieve, 4A type molecular sieve, 5A type molecular sieve, etc. Exemplarily, the mass fraction of the desiccant can be but is not limited to 50 parts, 55 parts, 60 parts, 65 parts, 70 parts, 75 parts, 80 parts, 85 parts, 90 parts, 95 parts, 100 parts or a range consisting of any two of these values.

[0062] In some embodiments, the tackifying resin includes one or more of rosin resin, epoxy resin, polyterpene resin and phenolic resin. For example, the mass fraction of the tackifying resin can be, but is not limited to, 10 parts, 15 parts, 20 parts, 25 parts, 30 parts, 35 parts, 40 parts, 45 parts, 50 parts or a range consisting of any two of these values.

[0063] In some embodiments, the antioxidant includes one or more of benzophenone, triazines, triazoles, hindered amines, salicylates and benzophenones. For example, the weight fraction of the antioxidant can be, but is not limited to, 1 part, 2 parts, 3 parts, 4 parts, 5 parts or a range consisting of any two of these values.

[0064] In some embodiments, the reinforcing fiber includes one or more of glass fiber, carbon fiber and polyester fiber. The length and diameter of the reinforcing fiber are not particularly limited and can be commonly used in the art. For example, the length of the glass fiber is 3 mm to 10 mm, which is a chopped glass fiber. Exemplarily, the length of the glass fiber can be 3 mm, 5 mm, 6 mm, 8 mm, 9 mm, 10 mm or a range consisting of any two of these values.

[0065] The cross section of the glass fiber is also not limited, for example, it can be flat or circular, and the cross section radius can be 7 μm to 15 μm. Specifically, the glass fiber can be one or more of E glass fiber, C glass fiber and E-CR glass fiber. In another example, the glass fiber can also be glass fiber cloth, and the diameter of the glass fiber cloth is 12 μm to 23 μm.

[0066] In some of the embodiments, the modified butyl sealant includes a first butyl rubber layer and a second butyl rubber layer disposed on at least one side of the first butyl rubber layer, and the second butyl rubber layer does not contain reinforcing fibers.

[0067] Specifically, the second butyl rubber layer comprises, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene and 200 to 400 parts of inorganic inert filler;

[0068] Optionally, the second butyl rubber layer further comprises: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an anti-aging agent.

[0069] Specifically, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.5). For example, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:1, 1:1.1, 1:1.2, 1:1.3, 1:1.4, 1:1.5, or a range consisting of any two of these values. Optionally, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.2).

[0070] In some embodiments, the total thickness of the modified butyl sealant is 0.5 mm to 2 mm. For example, the total thickness of the modified butyl sealant can be, but is not limited to, 0.5 mm, 0.6 mm, 0.8 mm, 1 mm, 1.2 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.8 mm, 2 mm, or a range consisting of any two of these values.

[0071] See also Figure 1 In one embodiment, the modified butyl sealant 100 includes a first butyl sealant layer 110. In other embodiments, see Figure 2 The modified butyl sealant 100 includes a first butyl rubber layer 110 and a second butyl rubber layer 120 disposed on one side of the first butyl rubber layer 110. In some other embodiments, please refer to Figure 3 The modified butyl sealant 100 includes a first butyl rubber layer 110 and two second butyl rubber layers 120 disposed on both sides of the first butyl rubber layer 110. Figure 3 In the modified butyl sealant 100 shown, the first and third layers are the second butyl rubber layer 120 without reinforcing fibers, and the second layer is the first butyl rubber layer 110 containing reinforcing fibers. The butyl rubber layer with reinforcing fibers added in the middle serves as a supporting skeleton to improve the strength and elastic modulus of the modified butyl sealant 100.

[0072] exist Figure 2 and Figure 3 In the embodiment, the ratio of the thickness of the first butyl rubber layer 110 to the total thickness of the second butyl rubber layer 120 is 1:(1-1.5). Figure 2 and Figure 3 In the embodiment, the ratio of the thickness of the first butyl rubber layer 110 to the total thickness of the second butyl rubber layer 120 is 1:(1-1.2).

[0073] exist Figure 1 In the modified butyl sealant 100, only a first butyl adhesive layer 110 is included. When applied to a photovoltaic module, the first butyl adhesive layer 110 is in direct contact with the glass, and not only has a bonding effect, but also has high strength and modulus. Figure 3 In the embodiment, the modified butyl sealant 100 has second butyl rubber layers 120 on both sides without reinforcing fibers, and a first butyl rubber layer 110 filled with reinforcing fibers in the middle. When used in photovoltaic modules, the second butyl rubber layers 120 on both sides play a role in bonding glass, and the first butyl rubber layer 110 in the middle mainly plays a role in improving strength and modulus, and has lower requirements for adhesion. Therefore, the amount of reinforcing fibers added can be increased, which is beneficial to further improve the strength of the modified butyl sealant 100 and reduce the risk of cracking.

[0074] In other embodiments, the present application also provides another modified butyl sealant, comprising: at least one butyl rubber layer and at least one fiber reinforcement layer stacked together, wherein along the thickness direction of the modified butyl sealant, the at least one butyl rubber layer and the at least one fiber reinforcement layer are alternately arranged.

[0075] The present application has found that battery components such as perovskite battery components use a combination of thermoplastic film and butyl adhesive to achieve water-blocking packaging, but the thermoplastic film itself has a low modulus and is prone to creep, shrinkage and other problems in high temperature environments. Traditional butyl sealants are thermoplastic sealants with poor cohesion and insufficient strength. They crack during long-term aging, which in turn causes the perovskite film layer to fall off and the components to fail. Based on this, some embodiments of the present application provide a modified butyl sealant, which can increase the elastic modulus of the butyl sealant and improve its strength by stacking at least one butyl layer and at least one fiber-reinforced layer. There will be no cracking problems under conditions of cold and hot cycle stress or aging tests, thereby improving the reliability of the components.

[0076] In addition, due to the poor cohesion of butyl sealant, problems such as glue penetration may occur during the assembly processing. Under high temperature conditions outdoors, if the butyl sealant is not strong enough, the internal packaging film may cause problems such as high-temperature flow driving the battery cells to shift, and short circuits caused by parallel cells. In some embodiments of the present application, by stacking at least one butyl sealant layer and at least one fiber reinforcement layer, the strength of the butyl sealant is improved, and the risk of high-temperature flow of the internal packaging film driving the battery cells to shift, and short circuits caused by parallel cells is reduced.

[0077] In some embodiments, the modified butyl sealant includes n+1 butyl rubber layers and n fiber reinforced layers, where n is an integer greater than or equal to 1, and along the thickness direction of the modified butyl sealant, the n+1 butyl rubber layers and the n fiber reinforced layers are alternately stacked.

[0078] Optionally, the ratio of the total thickness of the n+1 butyl rubber layers to the total thickness of the n fiber reinforced layers is 1:(1-3). For example, the ratio of the total thickness of the n+1 butyl rubber layers to the total thickness of the n fiber reinforced layers is 1:1, 1:1.2, 1:1.5, 1:1.8, 1:2, 1:2.2, 1:2.5, 1:2.8, 1:3 or a range consisting of any two of these values. Optionally, the ratio of the total thickness of the n+1 butyl rubber layers to the total thickness of the n fiber reinforced layers is 1:(1-2). Further optionally, the ratio of the total thickness of the n+1 butyl rubber layers to the total thickness of the n fiber reinforced layers is 1:(1-1.5).

[0079] It can be understood that the modified butyl sealant includes n+1 butyl rubber layers and n fiber reinforced layers, n is an integer greater than or equal to 1, and the n+1 butyl rubber layers and the n fiber reinforced layers are alternately arranged, that is, the outer sides of the modified butyl sealant are all butyl rubber layers. When used in photovoltaic modules, the adhesiveness of the outer butyl rubber layer is used to bond the glass, and the fiber reinforced layer located inside plays a role in improving the strength.

[0080] In some embodiments, the total thickness of the modified butyl sealant is 0.5 mm to 2 mm. For example, the total thickness of the modified butyl sealant can be, but is not limited to, 0.5 mm, 0.6 mm, 0.8 mm, 1 mm, 1.2 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.8 mm, 2 mm, or a range consisting of any two of these values.

[0081] The butyl rubber layer is a polymer of butyl rubber matrix and polyisoolefin, and is a thermoplastic material with coupling agent, antioxidant, inorganic filler, etc. added to achieve the bonding function. It is a non-cross-linked system.

[0082] Specifically, each butyl rubber layer independently comprises, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene (PIB) and 200 to 400 parts of inorganic inert filler;

[0083] Optionally, each butyl rubber layer also independently includes: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an anti-aging agent.

[0084] The specific butyl rubber, polyisobutylene, inorganic inert filler, desiccant, tackifying resin, silane coupling agent and antioxidant are the same as those mentioned above and will not be described in detail here.

[0085] In some embodiments, the material of each fiber reinforcement layer independently includes one or more of glass fiber, carbon fiber and polyester fiber. The length, diameter, etc. of the material of the fiber reinforcement layer are not particularly limited and can be commonly used in the art. For example, the length of the glass fiber is 3 mm to 10 mm, which is a chopped glass fiber. Exemplarily, the length of the glass fiber can be 3 mm, 5 mm, 6 mm, 8 mm, 9 mm, 10 mm or a range consisting of any two of these values.

[0086] The cross section of the glass fiber is also not limited, for example, it can be flat or circular, and the cross section radius can be 7 μm to 15 μm. Specifically, the glass fiber can be one or more of E glass fiber, C glass fiber and E-CR glass fiber. In another example, the glass fiber can also be glass fiber cloth, and the diameter of the glass fiber cloth is 12 μm to 23 μm.

[0087] See also Figure 4The modified butyl sealant 200 includes a fiber reinforced layer 220 and butyl rubber layers 210 disposed on both sides of the fiber reinforced layer 220. The butyl rubber layers on both sides are bonded to the glass, the fiber reinforced layer in the middle serves as a supporting skeleton, and the butyl rubber layers on both sides pass through the holes interlaced in the fiber reinforced layer to achieve bonding.

[0088] It can be understood that in other embodiments, the number of fiber reinforcement layers can be two, three, etc., and correspondingly, the number of butyl rubber layers can be three, four, etc., and a butyl rubber layer is provided between two adjacent fiber reinforcement layers. Figure 5 The modified butyl sealant includes a butyl rubber layer 210, a fiber-reinforced layer 220, a butyl rubber layer 210, a fiber-reinforced layer 220, and a butyl rubber layer 210 which are stacked in sequence.

[0089] It can be understood that when the number of fiber reinforced layers is greater than one, the materials of each fiber reinforced layer can be the same or different. Similarly, when the number of butyl rubber layers is greater than one, the materials of each butyl rubber layer can be the same or different.

[0090] The second aspect of the present application provides a method for preparing a modified butyl sealant, comprising the following steps:

[0091] Forming at least one butyl rubber layer and at least one fiber reinforcement layer stacked to prepare a modified butyl sealant, wherein the at least one butyl rubber layer and the at least one fiber reinforcement layer are alternately arranged along the thickness direction of the modified butyl sealant; or,

[0092] A butyl rubber layer filled with reinforcing fibers is formed to prepare a modified butyl sealant.

[0093] In some embodiments, the step of forming a butyl rubber layer filled with reinforcing fibers comprises:

[0094] The following raw materials are obtained by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene, 200 to 400 parts of inorganic inert filler and 20 to 60 parts of reinforcing fiber;

[0095] The raw materials are mixed to form a butyl rubber layer filled with reinforcing fibers.

[0096] Specifically, the step of mixing the raw materials includes: immersing the reinforcing fiber in a hydrochloric acid solution with a pH of 3 for 24 hours, then blending with an inorganic inert filler, etc. to obtain a pre-dispersion, and then mixing with butyl rubber and polyisobutylene.

[0097] In the above manner, the reinforcing fibers and fillers are pre-mixed to prepare a pre-dispersion, and then added to the rubber body, which does not affect the performance of the rubber itself.

[0098] In some other embodiments, the step of forming at least one butyl rubber layer and at least one fiber reinforced layer in a stacked manner comprises:

[0099] The following raw materials are obtained by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene and 200 to 400 parts of inorganic inert filler;

[0100] Mix the raw materials to form a butyl rubber layer;

[0101] The butyl rubber layer and the fiber reinforcement layer are laminated and compounded to form at least one butyl rubber layer and at least one fiber reinforcement layer which are stacked.

[0102] Specifically, in the step of laminating the butyl rubber layer and the fiber reinforcement layer, the lamination temperature is 50°C to 80°C and the pressure is 10MPa to 20MPa. For example, the lamination temperature may be, but not limited to, 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, 80°C or a range consisting of any two of these values. The lamination pressure may be, but not limited to, 10MPa, 12MPa, 14MPa, 15MPa, 16MPa, 18MPa, 20MPa or a range consisting of any two of these values.

[0103] The preparation method of the modified butyl sealant is simple to operate, highly feasible, and is conducive to industrial production.

[0104] The third aspect of the present application provides a use of the above-mentioned modified butyl sealant in the preparation of photovoltaic modules.

[0105] A fourth aspect of the present application provides a photovoltaic module, comprising the above-mentioned modified butyl sealant.

[0106] It is understood that the modified butyl sealant can be stacked with traditional thermoplastic films such as ethylene-vinyl acetate copolymer (EVA) films and used between solar cells and glass or back panels, and can also be used as a sealant at the edge of photovoltaic modules. Specifically, the modified butyl sealant achieves water-blocking encapsulation by applying glue or laying glue strips.

[0107] In some embodiments, the photovoltaic module may be, but is not limited to, a perovskite photovoltaic module or a heterojunction photovoltaic module.

[0108] In order to make the purpose and advantages of the present application clearer, the modified butyl sealant of the present application and its effects are further described in detail below in conjunction with specific examples. It should be understood that the specific examples described herein are only used to explain the present application and shall not be used to limit the present application. The following examples do not include other components except for inevitable impurities unless otherwise specified. The drugs and instruments used in the examples are conventionally selected in the art unless otherwise specified. The experimental methods for which specific conditions are not specified in the examples are implemented according to conventional conditions, such as the conditions described in the literature and books or the methods recommended by the manufacturer.

[0109] Example 1

[0110] This embodiment provides a modified butyl sealant having a structure as follows: Figure 1 As shown, the thickness is 1.5 mm, and the components, by mass, include: 260 parts of butyl rubber, 80 parts of polyisobutylene, 300 parts of inorganic inert filler (carbon black), 50 parts of glass fiber, 75 parts of desiccant (calcium oxide), 25 parts of tackifying resin (rosin resin), 6 parts of silane coupling agent and 4 parts of antioxidant (benzotriazole).

[0111] Example 2

[0112] This embodiment provides a modified butyl sealant having a structure as follows: Figure 2 As shown, the total thickness is 1.5mm, including the first butyl rubber layer and the second butyl rubber layer stacked at a thickness ratio of 1:1. Among them, by mass, the first butyl rubber layer includes: 200 parts of butyl rubber, 65 parts of polyisobutylene, 300 parts of inorganic inert filler (silicon dioxide), 35 parts of glass fiber, 60 parts of desiccant (calcium oxide), 25 parts of tackifying resin (rosin resin), 5 parts of silane coupling agent and 2 parts of anti-aging agent (benzotriazole). The second butyl rubber layer does not contain glass fiber, and the other composition is the same as the first butyl rubber layer.

[0113] Example 3

[0114] This embodiment provides a modified butyl sealant having a structure as follows: Figure 3 As shown, the total thickness is 1.5mm, including the second butyl rubber layer, the first butyl rubber layer and the second butyl rubber layer stacked in a thickness ratio of 1:2:1. Among them, by mass, the first butyl rubber layer includes: 160 parts of butyl rubber, 45 parts of polyisobutylene, 200 parts of inorganic inert filler (carbon black), 30 parts of glass fiber, 60 parts of desiccant (molecular sieve), 20 parts of tackifying resin (phenolic resin), 2 parts of silane coupling agent and 1.5 parts of anti-aging agent (benzophenone). The second butyl rubber layer does not contain glass fiber, and the other composition is the same as the first butyl rubber layer.

[0115] Example 4

[0116] This embodiment provides a modified butyl sealant having a structure as follows: Figure 4 As shown, the total thickness is 1.5mm, including a butyl rubber layer, a glass fiber reinforcement layer and a butyl rubber layer stacked in a thickness ratio of 1:2:1. Among them, by mass, the butyl rubber layer includes: 180 parts of butyl rubber, 40 parts of polyisobutylene, 260 parts of inorganic inert filler (silicon dioxide), 70 parts of desiccant (molecular sieve), 20 parts of tackifying resin (polyterpene resin), 3 parts of silane coupling agent and 2 parts of anti-aging agent (benzotriazole).

[0117] Example 5

[0118] This embodiment provides a modified butyl sealant, which is similar to Embodiment 4, except that the reinforcing fiber is carbon fiber.

[0119] Example 6

[0120] This embodiment provides a modified butyl sealant, which is similar to Embodiment 3, except that the thickness ratio of the second butyl rubber layer, the first butyl rubber layer and the second butyl rubber layer is different. In this embodiment, the thickness ratio of the second butyl rubber layer, the first butyl rubber layer and the second butyl rubber layer is 1.25:2:1.25.

[0121] Example 7

[0122] This embodiment provides a modified butyl sealant, which is similar to embodiment 4, except that the thickness ratio of the butyl rubber layer, the glass fiber reinforcement layer and the butyl rubber layer is different. In this embodiment, the thickness ratio of the butyl rubber layer, the glass fiber reinforcement layer and the butyl rubber layer is 1:2.2:1.

[0123] Comparative Example 1

[0124] Comparative Example 1 provides a traditional butyl sealant, which is similar to the modified butyl sealant of Example 1, except that it does not contain glass fiber.

[0125] Comparative Example 2

[0126] Comparative Example 2 provides a modified butyl sealant, which is similar to the modified butyl sealant of Example 1, except that the glass fiber in Example 1 is replaced by carbon black and white carbon black.

[0127] The modified butyl sealants of the above-mentioned embodiments and comparative examples were applied to photovoltaic modules, and the reliability of the photovoltaic modules was tested as shown in Table 1. In Table 1, the appearance of the butyl sealant in the third row refers to the appearance of the butyl sealant after the DH2000 test. The appearance of the butyl sealant in the fifth row refers to the appearance of the butyl sealant after the HAST48 test.

[0128] Table 1 Reliability data of different embodiments and comparative examples

[0129]

[0130] Please also read Figure 6 and Figure 7 , Figure 6 When the butyl sealant of Comparative Example 1 is applied to a photovoltaic module, cracks appear in the photovoltaic module after the TC aging test. Figure 7 The butyl sealant of Example 1 was applied to a photovoltaic module. The photovoltaic module had no cracks after the TC aging test and did not fail.

[0131] It can be seen from Table 1 that the modified butyl sealant of the above embodiment can effectively improve the cracking problem after the aging test and reduce the risk of component failure compared with the comparative example. In addition, by optimizing the structure of the modified butyl sealant, it is helpful to further reduce the risk of component failure.

[0132] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0133] The above-described embodiments only express several implementation methods of the present application, which is convenient for understanding the technical solution of the present application in detail, but it cannot be understood as limiting the scope of protection of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of the present application, several modifications and improvements can be made, which all belong to the scope of protection of the present application. It should be understood that the technical solutions obtained by those skilled in the art through logical analysis, reasoning or limited experiments on the basis of the technical solutions provided in the present application are all within the scope of protection of the claims attached to the present application. Therefore, the scope of protection of the patent of this application shall be based on the contents of the attached claims, and the description and drawings can be used to explain the contents of the claims.

Claims

1. A modified butyl sealant, characterized in that: include: At least one butyl rubber layer and at least one fiber reinforced layer are stacked and arranged alternately along the thickness direction of the modified butyl sealant.

2. The modified butyl sealant according to claim 1, characterized in that: It comprises n+1 layers of the butyl rubber layer and n layers of the fiber reinforced layer, wherein n is an integer greater than or equal to 1, and along the thickness direction of the modified butyl sealant, the n+1 layers of the butyl rubber layer and the n layers of the fiber reinforced layer are alternately stacked; Optionally, the ratio of the total thickness of the n+1 layers of butyl rubber layer to the total thickness of the n layers of fiber reinforced layer is 1:(1-3); Optionally, the ratio of the total thickness of the n+1 layers of butyl rubber layer to the total thickness of the n layers of fiber reinforced layer is 1:(1-2).

3. The modified butyl sealant according to claim 1 or 2, characterized in that: Calculated by weight, each of the butyl rubber layers independently comprises: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene and 200 to 400 parts of inorganic inert filler; Optionally, each of the butyl rubber layers independently comprises: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an anti-aging agent.

4. The modified butyl sealant according to claim 3, characterized in that: Each of the butyl rubber layers independently satisfies one or more of the following conditions: (1) The inorganic inert filler includes one or more of silicon dioxide, carbon black, talc, kaolin and calcium carbonate; (2) The desiccant includes one or more of molecular sieve, calcium oxide, calcium chloride, magnesium sulfate and activated alumina; (3) The tackifying resin includes one or more of rosin resin, epoxy resin, polyterpene resin and phenolic resin; (4) The antioxidant includes one or more of benzophenone, triazines, triazoles, hindered amines, salicylates and benzophenones.

5. The modified butyl sealant according to any one of claims 1 to 2 and 4, characterized in that: The material of each fiber-reinforced layer independently includes one or more of glass fiber, carbon fiber and polyester fiber.

6. A modified butyl sealant, characterized in that: It comprises a first butyl rubber layer, wherein the first butyl rubber layer is filled with reinforcing fibers.

7. The modified butyl sealant according to claim 6, characterized in that: The first butyl rubber layer comprises, by weight: 150 to 300 parts of butyl rubber, 30 to 100 parts of polyisobutylene, 200 to 400 parts of inorganic inert filler and 20 to 60 parts of reinforcing fiber; Optionally, the first butyl rubber layer further comprises: 50 to 100 parts of a desiccant, 10 to 50 parts of a tackifying resin, 1 to 10 parts of a silane coupling agent, and 1 to 5 parts of an anti-aging agent.

8. The modified butyl sealant according to claim 6, characterized in that: The modified butyl sealant further comprises a second butyl rubber layer disposed on at least one side of the first butyl rubber layer, wherein the second butyl rubber layer does not contain reinforcing fibers; Optionally, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.5); Optionally, the ratio of the thickness of the first butyl rubber layer to the total thickness of the second butyl rubber layer is 1:(1-1.2).

9. The modified butyl sealant according to any one of claims 6 to 8, characterized in that: The reinforcing fibers include one or more of glass fibers, carbon fibers and polyester fibers.

10. A method for preparing a modified butyl sealant, characterized in that: The steps include: Forming at least one butyl rubber layer and at least one fiber reinforcement layer in a stacked arrangement to prepare a modified butyl sealant, wherein the at least one butyl rubber layer and the at least one fiber reinforcement layer are alternately arranged along the thickness direction of the modified butyl sealant; or, A butyl rubber layer filled with reinforcing fibers is formed to prepare a modified butyl sealant.

11. Use of the modified butyl sealant according to any one of claims 1 to 9 in the preparation of photovoltaic modules.

12. A photovoltaic module, characterized in that: The invention comprises the modified butyl sealant according to any one of claims 1 to 9 or the modified butyl sealant prepared by the preparation method according to claim 10.

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