Special cable applied to solar photovoltaic module and preparation process thereof

Abstract

The invention relates to the technical field of cables, and particularly discloses a special cable applied to a solar photovoltaic module and a preparation process of the special cable. The invention relates to a special cable applied to a solar photovoltaic module. The special cable sequentially comprises a high-conductivity copper conductor, a weather-resistant insulating layer, an anti-ultraviolet sheath and an enhanced fiber braid layer from inside to outside, the weather-resistant insulating layer is prepared from the following components in parts by weight: 80 to 125 parts of polyethylene, 2 to 8 parts of maleic anhydride, 1 to 5 parts of allyloxyacetophenone, 0.3 to 0.9 part of antioxidant, 2 to 6 parts of benzophenone, 1 to 3 parts of crosslinking aid, 5 to 10 parts of modified nano calcium carbonate and 5 to 10 parts of nano aluminum oxide. The special cable applied to the solar photovoltaic module prepared by the invention has excellent weather resistance, and can keep excellent electrical performance and mechanical performance under extreme weather conditions.

Description

Technical Field

[0001] The present application relates to the field of cable technology, and in particular to a special cable used in solar photovoltaic modules and a preparation process thereof. Background Art

[0002] With the rapid development of solar photovoltaic technology, the connection cables of photovoltaic modules are key components, and their performance is directly related to the stability and efficiency of the entire photovoltaic system. Traditional solar photovoltaic module connection cables usually use standard cable materials. These materials perform well under certain environmental conditions, but are prone to problems such as insulation aging and conductor corrosion in harsh environments such as long-term ultraviolet radiation and alternating high and low temperatures. The cables currently on the market still need to be improved in terms of weather resistance and anti-aging, especially in terms of performance under extreme climatic conditions. The lack of weather resistance of traditional cables leads to reduced reliability of photovoltaic systems in environments such as high-intensity ultraviolet rays and extreme temperatures, which in turn affects the overall power generation efficiency and service life of the system. Summary of the invention

[0003] In order to solve at least one of the above technical problems, the present application provides a special cable applied to solar photovoltaic modules and a preparation process thereof.

[0004] On the one hand, the present application provides a special cable for use in solar photovoltaic modules, which includes, from the inside out, a high-conductivity copper conductor, a weather-resistant insulation layer, an anti-ultraviolet sheath, and a reinforced fiber braided layer; The weather-resistant insulating layer comprises the following components in parts by weight: 80-125 parts of polyethylene, 2-8 parts of maleic anhydride, 1-5 parts of acryloxyacetophenone, 0.3-0.9 parts of antioxidant, 2-6 parts of benzophenone, 1-3 parts of crosslinking aid, 5-10 parts of modified nano calcium carbonate and 5-10 parts of nano aluminum oxide.

[0005] By adopting the above technical scheme, the special cable used in the solar photovoltaic module in the present application combines the performance of the weather-resistant insulation layer, the anti-ultraviolet sheath and the reinforced fiber braid layer, and effectively improves the weather resistance of the cable through the multi-layer protection mechanism, ensuring the electrical performance and mechanical stability of the cable in extreme climate environments. In the weather-resistant insulation layer, polyethylene is used as a matrix material to provide basic mechanical strength and insulation performance. Maleic anhydride modifies polyethylene to increase its polarity, promote compatibility with other components, and facilitate cross-linking reactions. Propylene oxyacetophenone, as a light stabilizer, protects the cable from ultraviolet damage. Antioxidants prevent aging caused by oxidation during processing or use. Benzophenone can work with propenyloxyacetophenone to enhance the protection against ultraviolet rays. Cross-linking aids promote cross-linking between material molecules, thereby improving physical properties, heat resistance and mechanical strength. Modified nano calcium carbonate can improve the mechanical properties of cables and improve the chemical resistance of cables. Nano alumina can improve the wear resistance, hardness and thermal stability of cables.

[0006] Optionally, the preparation method of the modified nano-calcium carbonate comprises the following steps: adding nano-calcium carbonate to a 30wt% phosphoric acid solution, letting it stand for 20-40 minutes, taking it out, drying it, adding octadecyltrichlorosilane, mixing and stirring for 15-30 minutes, and drying it to obtain the modified nano-calcium carbonate.

[0007] By adopting the above technical solution, the surface properties of the modified nano calcium carbonate are changed, and the compatibility with polyethylene is improved, so that it can be better dispersed in the composite material, improve the overall performance of the cable, and enhance the mechanical properties, thermal stability and processing performance.

[0008] Optionally, the weight ratio of the nano calcium carbonate to octadecyltrichlorosilane is (30-40): (1-4).

[0009] Optionally, the weather-resistant insulating layer further comprises 2-6 parts by weight of modified potassium hexatitanate whiskers.

[0010] Optionally, the preparation method of the modified potassium hexatitanate whisker comprises the following steps: adding the dried potassium hexatitanate to anhydrous ethanol to form a suspension, adding 5-7% of the mass of the potassium hexatitanate whisker K550 coupling agent, stirring at 30-35° C. for 40-60 min, filtering and drying to obtain the modified potassium hexatitanate whisker.

[0011] By adopting the above technical solution, the surface modification of the coupling agent can improve the interfacial bonding between potassium hexatitanate whiskers and polyethylene and reduce interfacial defects. By adding modified potassium hexatitanate whiskers, the weather resistance of the cable may be enhanced, especially in outdoor environments, and can better resist the influence of ultraviolet rays, humidity and other harsh conditions.

[0012] Optionally, the antioxidant is antioxidant 1010.

[0013] Optionally, the cross-linking aid is tripropylene cyanurate.

[0014] Optionally, the UV-resistant sheath consists of a polyurethane elastomer and an antioxidant.

[0015] Optionally, the reinforced fiber braided layer is braided from aramid fibers.

[0016] In a second aspect, the present application provides a preparation process of the above-mentioned special cable applied to solar photovoltaic modules, comprising the following steps: A1. Take polyethylene, add antioxidant, benzophenone and maleic anhydride, mix, mix for 5-10 minutes, then add crosslinking aid, continue mixing for 12-18 minutes to obtain a mixed material; A2, mixing the mixed material obtained in step A1 with acryloxyacetophenone, heating at 140-145° C. and 15 MPa for 5-10 min, irradiating with ultraviolet light, and then extruding and coating the mixed material on the surface of a conductive copper conductor to obtain a weather-resistant insulating layer; A3. The outer surface of the weather-resistant insulation layer is coated with an anti-ultraviolet sheath and a reinforced fiber braided layer in sequence to obtain the special cable used in solar photovoltaic modules.

[0017] By adopting the above technical solution, the cable prepared in the present application has excellent weather resistance, simple preparation process, improved production efficiency, and is conducive to large-scale promotion and application.

[0018] In summary, the present invention includes at least one of the following beneficial technical effects: 1. The special cables used in solar photovoltaic modules in this application combine the performance of weather-resistant insulation layer, UV-resistant sheath and reinforced fiber braid layer, and effectively improve the weather resistance of the cable through a multi-layer protection mechanism, ensuring the electrical performance and mechanical stability of the cable in extreme climate environments.

[0019] 2. The cable prepared in this application has excellent weather resistance, a simple preparation process, improved production efficiency, and is conducive to large-scale promotion and application. DETAILED DESCRIPTION

[0020] The present application is further described in detail below with reference to the embodiments. Specific embodiments

[0021] Preparation Example 1 This preparation example provides a preparation method for modified nano-calcium carbonate: adding nano-calcium carbonate to a 30wt% phosphoric acid solution, standing for 20 minutes, taking it out, drying it, then adding octadecyltrichlorosilane, mixing and stirring for 40 minutes, and drying it to obtain modified nano-calcium carbonate.

[0022] Wherein, the weight ratio of nano calcium carbonate to octadecyltrichlorosilane is 30:1.

[0023] Preparation Example 2 This preparation example provides a preparation method for modified nano-calcium carbonate: adding nano-calcium carbonate to a 30wt% phosphoric acid solution, standing for 30 minutes, taking it out, drying it, then adding octadecyltrichlorosilane, mixing and stirring for 23 minutes, and drying it to obtain modified nano-calcium carbonate.

[0024] Wherein, the weight ratio of nano calcium carbonate to octadecyltrichlorosilane is 35:2.

[0025] Preparation Example 3 This preparation example provides a preparation method for modified nano-calcium carbonate: adding nano-calcium carbonate to a 30wt% phosphoric acid solution, standing for 40 minutes, taking it out, drying it, then adding octadecyltrichlorosilane, mixing and stirring for 30 minutes, and drying it to obtain modified nano-calcium carbonate.

[0026] Wherein, the weight ratio of nano calcium carbonate to octadecyltrichlorosilane is 40:4.

[0027] Preparation Example 4 This preparation example provides a preparation method for modified potassium hexatitanate whiskers: add the dried hexatitanium to anhydrous ethanol to form a suspension, add 5% of the mass of the potassium hexatitanate whiskers K550 coupling agent, stir at 30°C for 60 minutes, filter and dry to obtain the modified potassium hexatitanate whiskers.

[0028] Preparation Example 5 This preparation example provides a preparation method for modified potassium hexatitanate whiskers: add the dried hexatitanium to anhydrous ethanol to form a suspension, add 6% K550 coupling agent by weight of the potassium hexatitanate whiskers, stir at 32°C for 50 minutes, filter and dry to obtain the modified potassium hexatitanate whiskers.

[0029] Preparation Example 4 This preparation example provides a preparation method for modified potassium hexatitanate whiskers: add the dried hexatitanium to anhydrous ethanol to form a suspension, add 7% K550 coupling agent by weight of the potassium hexatitanate whiskers, stir at 35°C for 40 minutes, filter and dry to obtain the modified potassium hexatitanate whiskers. Example 1

[0030] This embodiment provides a special cable applied to a solar photovoltaic module, which includes, from the inside to the outside, a high-conductivity copper conductor, a weather-resistant insulation layer, an anti-ultraviolet sheath, and a reinforced fiber braided layer.

[0031] The weather-resistant insulating layer comprises the following components in parts by weight: 80-125 parts of polyethylene, 2-8 parts of maleic anhydride, 1-5 parts of acryloxyacetophenone, 0.3-0.9 parts of antioxidant 1010, 2-6 parts of benzophenone, 1-3 parts of tripropylene cyanurate, 5-10 parts of modified nano calcium carbonate and 5-10 parts of nano aluminum oxide.

[0032] Wherein, the modified nano calcium carbonate is prepared by Preparation Example 1.

[0033] The UV-resistant jacket is composed of polyurethane elastomer and antioxidant in a weight ratio of 80:1.

[0034] The reinforced fiber braided layer is braided from aramid fibers.

[0035] A preparation process for a special cable used in a solar photovoltaic module, characterized by comprising the following steps: A1. Take polyethylene, add antioxidant, benzophenone and maleic anhydride, mix, mix for 5-10 minutes, then add crosslinking aid, continue mixing for 12-18 minutes to obtain a mixed material; A2, mixing the mixed material obtained in step A1 with acryloxyacetophenone, heating at 140-145° C. and 15 MPa for 5-10 min, irradiating with ultraviolet light, and then extruding and coating the mixed material on the surface of a conductive copper conductor to obtain a weather-resistant insulating layer; A3. The outer surface of the weather-resistant insulation layer is coated with an anti-ultraviolet sheath and a reinforced fiber braided layer in sequence to obtain the special cable used in solar photovoltaic modules. Example 2

[0036] This embodiment provides a special cable applied to a solar photovoltaic module, which includes, from the inside to the outside, a high-conductivity copper conductor, a weather-resistant insulation layer, an anti-ultraviolet sheath, and a reinforced fiber braided layer.

[0037] The weather-resistant insulating layer comprises the following components in parts by weight: 100 parts of polyethylene, 6 parts of maleic anhydride, 3 parts of acryloxyacetophenone, 0.6 parts of antioxidant 1010, 4 parts of benzophenone, 2 parts of tripropylene cyanurate, 7 parts of modified nano calcium carbonate and 8 parts of nano aluminum oxide.

[0038] Wherein, the modified nano calcium carbonate is prepared by Preparation Example 1.

[0039] The UV-resistant jacket is composed of polyurethane elastomer and antioxidant in a weight ratio of 80:1.

[0040] The reinforced fiber braided layer is braided from aramid fibers.

[0041] A preparation process for a special cable used in a solar photovoltaic module, characterized by comprising the following steps: A1. Take polyethylene, add antioxidant, benzophenone and maleic anhydride, mix, mix for 8 minutes, then add crosslinking aid, continue mixing for 15 minutes to obtain a mixed material; A2, mixing the mixed material obtained in step A1 with acryloxyacetophenone, heating at 142° C. and 15 MPa for 8 min, irradiating with ultraviolet light, and then extruding and coating the mixed material on the surface of a conductive copper conductor to obtain a weather-resistant insulating layer; A3. The outer surface of the weather-resistant insulation layer is coated with an anti-ultraviolet sheath and a reinforced fiber braided layer in sequence to obtain the special cable used in solar photovoltaic modules. Example 3

[0042] This embodiment provides a special cable applied to a solar photovoltaic module, which includes, from the inside to the outside, a high-conductivity copper conductor, a weather-resistant insulation layer, an anti-ultraviolet sheath, and a reinforced fiber braided layer.

[0043] The weather-resistant insulating layer comprises the following components in parts by weight: 125 parts of polyethylene, 8 parts of maleic anhydride, 5 parts of acryloxyacetophenone, 0.9 parts of antioxidant 1010, 6 parts of benzophenone, 3 parts of tripropylene cyanurate, 10 parts of modified nano calcium carbonate and 10 parts of nano aluminum oxide.

[0044] Wherein, the modified nano calcium carbonate is prepared by Preparation Example 1.

[0045] The UV-resistant jacket is composed of polyurethane elastomer and antioxidant in a weight ratio of 80:1.

[0046] The reinforced fiber braided layer is braided from aramid fibers.

[0047] A preparation process for a special cable used in a solar photovoltaic module, characterized by comprising the following steps: A1. Take polyethylene, add antioxidant, benzophenone and maleic anhydride, mix, mix for 10 minutes, then add crosslinking aid, continue mixing for 12 minutes to obtain a mixed material; A2, mixing the mixed material obtained in step A1 with acryloxyacetophenone, heating at 145° C. and 15 MPa for 5 min, irradiating with ultraviolet light, and then extruding and coating the mixed material on the surface of a conductive copper conductor to obtain a weather-resistant insulating layer; A3. The outer surface of the weather-resistant insulation layer is coated with an anti-ultraviolet sheath and a reinforced fiber braided layer in sequence to obtain the special cable used for solar photovoltaic modules. Comparative Example 1 The difference between this comparative example and Example 2 is that, when preparing the special cable used for solar photovoltaic modules, unmodified nano-calcium carbonate is used to replace the modified nano-calcium carbonate in equal amounts.

[0048] Comparative Example 2 The difference between this comparative example and Example 2 is that maleic anhydride is not added when preparing the special cable used in the solar photovoltaic module.

[0049] Comparative Example 3 The difference between this comparative example and Example 2 is that no acryloxyacetophenone is added when preparing the special cable used in the solar photovoltaic module. Example 4

[0050] The difference between this embodiment and embodiment 2 is that, when preparing the special cable used in the solar photovoltaic module, the modified nano calcium carbonate is prepared by the preparation example 2. Example 5

[0051] The difference between this embodiment and embodiment 2 is that, when preparing the special cable used in the solar photovoltaic module, the modified nano calcium carbonate is prepared by preparation example 3. Example 6

[0052] The difference between this embodiment and embodiment 4 is that when preparing the special cable used for solar photovoltaic modules, the weather-resistant insulating layer further includes 2 parts by weight of potassium hexatitanate whiskers. Example 7

[0053] The difference between this embodiment and embodiment 4 is that when preparing the special cable used in the solar photovoltaic module, the weather-resistant insulating layer further includes 2 parts by weight of the modified potassium hexatitanate whiskers prepared in preparation example 4. Example 8

[0054] The difference between this embodiment and embodiment 4 is that when preparing the special cable used in the solar photovoltaic module, the weather-resistant insulating layer further includes 4 parts by weight of the modified potassium hexatitanate whiskers prepared in preparation example 4. Example 9

[0055] The difference between this embodiment and embodiment 4 is that when preparing the special cable used in the solar photovoltaic module, the weather-resistant insulating layer further includes 6 parts by weight of the modified potassium hexatitanate whiskers prepared in preparation example 4. Example 10

[0056] The difference between this embodiment and Embodiment 8 is that, when preparing the special cable used in the solar photovoltaic module, the modified potassium hexatitanate whisker is prepared by Preparation Example 5. Embodiment 11

[0057] The difference between this embodiment and embodiment 8 is that, when preparing the special cable used in the solar photovoltaic module, the modified potassium hexatitanate whisker is prepared by the preparation example 6.

[0058] High temperature resistance: Tested in accordance with GB / T 3512-2014, the tensile strength before and after exposure to hot air at 120°C for 24 hours is tested, and the tensile strength retention rate is calculated. The tensile strength retention rate = (tensile strength after high temperature treatment / initial tensile strength) × 100%; Low temperature resistance: After placing the photovoltaic cable samples in an environment of -45°C for 7 days, the elongation at break was tested in accordance with GB / T 3512-2014 and the elongation at break was calculated. The elongation at break retention rate = (elongation at break after low temperature treatment / initial elongation at break) × 100% The experimental test results of Examples 1-11 and Comparative Examples 1-3 are shown in Table 1.

[0059] Table 1 - Experimental test results of Examples 1-11 and Comparative Examples 1-3

[0060] Results Analysis Combining the experimental test results of Examples 1-3 and Table 1, it can be seen that the special cables used for solar photovoltaic modules prepared according to the raw material ratio and preparation process of the present application have good weather resistance and can be used in extreme environments. The difference between Comparative Example 1 and Example 2 is that when preparing special cables used for solar photovoltaic modules, unmodified nano-calcium carbonate is selected to replace the modified nano-calcium carbonate in equal amounts. The difference between Comparative Example 2 and Example 2 is that when preparing special cables used for solar photovoltaic modules, maleic anhydride is not added. The difference between Comparative Example 3 and Example 2 is that when preparing special cables used for solar photovoltaic modules, propenyloxyacetophenone is not added. Combining the experimental test results of Table 1, it can be seen that when preparing special cables used for solar photovoltaic modules, the use of modified nano-calcium carbonate, maleic anhydride and propenyloxyacetophenone can better improve the comprehensive performance of the obtained special cables used for solar photovoltaic modules.

[0061] Combining Examples 4-5 and Table 1, it can be seen that the cable made from the modified nano-calcium carbonate prepared in Preparation Example 2 has better comprehensive performance.

[0062] Combining Examples 6-11 and Table 1, it can be seen that the cables made of modified nano-calcium carbonate by adding modified potassium hexatitanate whiskers, especially the modified potassium hexatitanate whiskers prepared in Preparation Example 5, have better comprehensive performance.

[0063] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A special cable used in solar photovoltaic modules, characterized in that: From the inside out, it includes high conductivity copper conductor, weather-resistant insulation layer, UV-resistant sheath and reinforced fiber braid layer; The weather-resistant insulating layer comprises the following components in parts by weight: 80-125 parts of polyethylene, 2-8 parts of maleic anhydride, 1-5 parts of acryloxyacetophenone, 0.3-0.9 parts of antioxidant, 2-6 parts of benzophenone, 1-3 parts of crosslinking aid, 5-10 parts of modified nano calcium carbonate and 5-10 parts of nano aluminum oxide.

2. The special cable used for solar photovoltaic modules according to claim 1, characterized in that: The preparation method of the modified nano calcium carbonate comprises the following steps: adding nano calcium carbonate into a 30wt% phosphoric acid solution, standing for 20-40 minutes, taking out, drying, adding octadecyltrichlorosilane, mixing and stirring for 15-30 minutes, drying, and obtaining the modified nano calcium carbonate.

3. The special cable used for solar photovoltaic modules according to claim 2, characterized in that: The weight ratio of the nano calcium carbonate to octadecyl trichlorosilane is (30-40): (1-4).

4. The special cable for solar photovoltaic modules according to claim 1, characterized in that: The weather-resistant insulating layer further comprises 2-6 parts by weight of modified potassium hexatitanate whiskers.

5. The special cable used for solar photovoltaic modules according to claim 4, characterized in that: The preparation method of the modified potassium hexatitanate whisker comprises the following steps: adding the dried hexatitanium into anhydrous ethanol to prepare a suspension, adding 5-7% of the mass of the potassium hexatitanate whisker K550 coupling agent, stirring at 30-35° C. for 40-60 minutes, filtering and drying to obtain the modified potassium hexatitanate whisker.

6. The special cable used for solar photovoltaic modules according to claim 1, characterized in that: The antioxidant is antioxidant 1010.

7. The special cable used for solar photovoltaic modules according to claim 1, characterized in that: The cross-linking auxiliary agent is tripropylene cyanurate.

8. The special cable used for solar photovoltaic modules according to claim 1, characterized in that: The anti-ultraviolet sheath consists of polyurethane elastomer and antioxidant.

9. The special cable used for solar photovoltaic modules according to claim 1, characterized in that: The reinforced fiber braided layer is braided and formed by aramid fibers.

10. A process for preparing a special cable used for solar photovoltaic modules according to any one of claims 1 to 9, characterized in that: The steps include: A1. Take polyethylene, add antioxidant, benzophenone and maleic anhydride, mix, mix for 5-10 minutes, then add crosslinking aid, continue mixing for 12-18 minutes to obtain a mixed material; A2, mixing the mixed material obtained in step A1 with acryloxyacetophenone, heating at 140-145° C. and 15 MPa for 5-10 min, irradiating with ultraviolet light, and then extruding and coating the mixed material on the surface of a conductive copper conductor to obtain a weather-resistant insulating layer; A3. The outer surface of the weather-resistant insulation layer is coated with an anti-ultraviolet sheath and a reinforced fiber braided layer in sequence to obtain the special cable used in solar photovoltaic modules.

Images