Light photovoltaic module back plate packaging material and preparation method thereof

Abstract

The invention discloses a light photovoltaic module back plate packaging material. The back plate packaging material sequentially comprises a modified resin weather-proof layer, a resin fiber reinforcement layer and a modified resin bonding layer from top to bottom, the modified resin bonding layer accounts for 5%-30% of the rear plate in parts by weight; the resin fiber reinforced layer accounts for 40-90% of the rear plate in parts by weight; the modified resin weather-proof layer accounts for 5%-30% of the weight of the rear plate, and the light photovoltaic module rear plate packaging material adopts a three-layer structural design, namely the modified resin weather-proof layer, the resin fiber reinforced layer and the modified resin bonding layer from top to bottom. The material structure not only improves the strength of the product, but also has better weather resistance, thereby better protecting the internal structure of the assembly and prolonging the service life; meanwhile, the light photovoltaic module back plate packaging material adopts an integrated hot pressing process, so that the production efficiency is improved, the production time and cost are reduced, the production process is optimized, and the energy consumption is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of packaging materials, and in particular relates to a lightweight photovoltaic module rear plate packaging material and a preparation method thereof. Background Art

[0002] With the continuous growth of global energy demand and increasingly severe environmental problems, solar photovoltaic technology, as a clean and renewable energy solution, has received widespread attention and rapid development. Photovoltaic modules are the core components of solar photovoltaic systems, and their performance and reliability directly affect the power generation efficiency and service life of the entire system. Photovoltaic modules are usually composed of front panels, photovoltaic cells, packaging materials, back panels, etc., among which the selection of back materials has an important impact on the overall performance of the module.

[0003] The back panel material of traditional photovoltaic modules is mainly glass. This is because glass has excellent mechanical strength and can protect photovoltaic cells from the external environment for a long time. However, glass as a back panel material also has some obvious defects: heavy weight, high density of glass, resulting in a large weight of the entire photovoltaic module, which not only increases the difficulty and cost of transportation and installation, but also brings a greater burden to certain specific application scenarios (such as rooftop photovoltaic systems); fragile, although glass materials have a certain strength, but it is easy to break when impacted or in extreme weather (such as hail, strong winds, etc.), thus affecting the service life and reliability of photovoltaic modules; high production energy consumption, the manufacturing process of glass requires high-temperature melting, high energy consumption, high production cost, and also brings a greater environmental burden.

[0004] Based on the above problems, researchers and companies have been exploring and developing new photovoltaic module backplane materials, hoping to reduce weight, improve production efficiency and reduce environmental impact while maintaining or improving module performance. Among them, lightweight, high-efficiency and environmentally friendly packaging materials have become a hot research direction. In recent years, some new materials and technologies have been introduced into the research of photovoltaic module backplanes, such as aluminum plates, carbon fibers and resin material surface coating technology. These materials are lighter than traditional glass, but their weather resistance and mechanical strength are relatively low, and they are prone to aging, yellowing, and powdering during long-term use. The resin material surface coating technology is to apply the coating on the numerical material and then mature and fix it through process methods such as heat baking. However, this method is inefficient in the production process, the steps are cumbersome, and the coating has a strong odor, which is not good for personnel health.

[0005] In addition, there are some problems with the existing lightweight photovoltaic module back panel packaging materials. First, the adhesion of the coating on the surface of the resin-coated board is relatively low, which means that the bonding force between the coating and the board substrate may not be strong enough during the coating process, and the coating is prone to fall off or peeling, which may affect the appearance quality and durability of the product. Secondly, the resin-coated board is easily affected by light, heat and oxygen during use and ages, which also affects the stability and service life of the coating. The aged coating may change color, crack, fall off, etc., thereby reducing the overall performance of the product.

[0006] The best existing technical solution is the patented technology of Beijing Jinmao Green Building Technology Co., Ltd., with the patent number: CN 116487460 A. As shown in the patented technical document, the encapsulation material is formed by two preparation methods, namely, a thermosetting powder resin preparation method and a thermosetting liquid resin preparation method. After spraying resin powder onto glass fiber or glass fiber pre-impregnated with liquid resin, it is pre-cured by hot pressing or hot baking, and then hot pressing, surface corona or plasma treatment, coating, oven aging and other processes are finally completed to complete the encapsulation material. The production process is relatively cumbersome, with low production efficiency and high energy consumption: the technology uses fluorocarbon and acrylic coating for bonding and weathering, which is not weather-resistant enough. The components are prone to yellowing, cracking and delamination after long-term outdoor use.

[0007] Therefore, in order to solve the following problems existing in the prior art: 1. Durability and stability problems of existing lightweight photovoltaic module back panel packaging materials; 2. Poor adhesion and bonding strength of lightweight photovoltaic module back panels due to external influences; 3. Poor strength and hardness of lightweight photovoltaic back panels, which lead to more prone to hidden cracks in batteries during transportation; It has become an urgent problem to develop a lightweight photovoltaic module back panel material that can maintain good performance and solve the defects of the prior art. Summary of the invention

[0008] The purpose of the present invention is to provide a lightweight photovoltaic module back panel packaging material, specifically a back panel modified by thermal composite resin, both of which are aimed at solving the above-mentioned problems and providing a high-performance, environmentally friendly photovoltaic module back panel material.

[0009] To achieve the above object, the technical solution adopted by the present invention is: a lightweight photovoltaic module rear panel packaging material, wherein the rear panel packaging material comprises, from top to bottom, a modified resin weather-resistant layer, a resin fiber reinforcement layer, and a modified resin bonding layer;

[0010] The modified resin bonding layer accounts for 5%-30% of the weight of the rear plate;

[0011] The resin fiber reinforcement layer accounts for 40%-90% of the weight of the rear plate;

[0012] The modified resin weather-resistant layer accounts for 5%-30% of the weight of the rear plate.

[0013] The technical solution further improved in the above technical solution is as follows:

[0014] 1. In the above scheme, the modified resin bonding layer includes the following components: resin as the main component, accounting for 60%-70%;

[0015] Maleic anhydride grafted modified PP is used as a compatibilizer, with a content of 15% to 20%;

[0016] Specific acrylic ester tackifier, content of 10% to 20%;

[0017] Add appropriate amount of antioxidant 0.5%-1.5% and light stabilizer 0.3%~0.8%.

[0018] The preparation method of the modified resin bonding layer comprises: firstly mixing the materials by a stirrer, then granulating the materials by an extruder, and then casting the materials into a film.

[0019] 2. In the above scheme, the resin fiber reinforcement layer includes the following components: resin as the main component, accounting for 60% to 90%;

[0020] Glass fiber is a reinforcing material, and its content accounts for 10% to 40% of the total;

[0021] The additive composition includes the following components: 0.5%-2% of coupling agent, 0.1%-0.5% of antioxidant, and 0.3%-0.8% of lubricant.

[0022] The method for preparing the resin fiber reinforcement layer comprises: impregnating glass fibers with PP resin, laying them flat in a crisscross stacking manner, and molding them at high temperature and high pressure using a flat machine.

[0023] 3. In the above scheme, the modified resin weather-resistant layer includes the following components, with the resin as the main material accounting for 70%-90%.

[0024] UV absorber 0.1%-1%,

[0025] Light stabilizer 0.5%-1%,

[0026] Antioxidants 0.5%-1.2%,

[0027] Talc 10%-15%,

[0028] Lubricant 0.2%~0.5%.

[0029] The modified resin weather-resistant layer preparation method comprises: firstly mixing the materials by a stirrer, then granulating the materials by an extruder, and then casting the materials into a film.

[0030] 4. In the above scheme, the resins in the modified resin weather-resistant layer, the resin fiber reinforced layer, and the modified resin adhesive layer are respectively one or more of polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), ABS resin, polycarbonate (PC), polyamide (nylon), polyphenylene ether (PPO), polyurethane (PU), polyester (PET, PBT), and PMMA, and the resins in the modified resin weather-resistant layer, the resin fiber reinforced layer, and the modified resin adhesive layer may be the same or different.

[0031] Preferably, the polypropylene in the modified resin adhesive layer is copolymerized polypropylene (PP-R);

[0032] The polypropylene in the resin fiber reinforcement layer is homopolymer polypropylene (PP-H);

[0033] The polypropylene in the modified resin weather-resistant layer is homopolymer polypropylene (PP-H).

[0034] 5. In the above scheme, the thickness of the modified resin bonding layer material ranges from 100 to 2000 μm;

[0035] The thickness of the modified resin weather-resistant layer material ranges from 100 to 2000 μm;

[0036] The thickness of the resin fiber reinforced layer material ranges from 900 to 3000 μm.

[0037] 6. In the above scheme, the modified resin bonding layer material has an adhesion of 100N / cm to PEO or EVA.

[0038] 7. In the above solution, the visible light reflectivity of the modified resin adhesive layer material is ≥90%.

[0039] Another technical solution of the present invention is: a method for preparing a lightweight photovoltaic module back plate packaging material, comprising the following steps:

[0040] The adhesive layer and the weather-resistant layer are extruded by a screw extruder; a reinforcing layer is sandwiched between the weather-resistant layer and the adhesive layer; and the composite three-layer structure is laminated by a hot press to obtain the photovoltaic back panel;

[0041] The thermal compounding temperature is ≥165° C., and the thermal compounding pressure is 0.1-1 mPa.

[0042] Another technical solution of the present invention is: a method for preparing a lightweight photovoltaic module, comprising the following steps:

[0043] On the photovoltaic glass, a layer of POE film is laid flat, followed by laying a battery string array, and then another layer of POE film is laid flat, and finally a layer of lightweight photovoltaic module rear panel packaging material is laid flat to prepare a laminated module using the packaging material;

[0044] The stacked components are placed in a laminator for lamination, and the lamination is performed in sections. After the lamination is completed, a laminated component using the packaging material is prepared;

[0045] The laminated assembly is framed and fixed with a photovoltaic aluminum frame, and finally a lightweight photovoltaic assembly using the packaging material is prepared.

[0046] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art:

[0047] 1. The lightweight photovoltaic module back panel packaging material of the present invention adopts a three-layer structure design: from top to bottom, it is a modified resin weather-resistant layer, a resin fiber reinforcement layer, and a modified resin bonding layer. This material structure not only improves the strength of the product, but also has better weather resistance, thereby better protecting the internal structure of the module and extending the service life.

[0048] 2. The lightweight photovoltaic module back panel packaging material of the present invention adopts an integrated hot pressing process, which not only improves production efficiency, reduces production time and cost, but also optimizes the production process and reduces energy consumption.

[0049] 3. The lightweight photovoltaic module back panel packaging material of the present invention has a high variability of modified resin, which can meet the different needs of different application scenarios. It has excellent aging resistance and mechanical strength and can remain stable in various environments, thereby ensuring the high performance and service life of the packaging material. The thermoplastic properties are also more in line with the concepts of environmental protection and sustainable development. DETAILED DESCRIPTION

[0050] The present invention will be further described below in conjunction with embodiments:

[0051] Embodiment 1:

[0052] A packaging material for a lightweight photovoltaic module, the structure of which is a modified resin bonding layer, a resin glass fiber reinforcement layer, and a modified resin weathering layer from top to bottom, wherein:

[0053] Preferably, as the weather-resistant layer of the photovoltaic module encapsulation material, homopolymer polypropylene (PP-H) is selected as the main material of the product, accounting for 84%, and the melt flow rate is selected as MFR of 5g / 10min to ensure the fluidity and uniformity of the extrusion process. The talcum powder is selected as 800 mesh with a particle size of 10um, accounting for 13% of the total, so that the hardness, heat resistance and appearance quality of the product are better. The ultraviolet absorber is a benzotriazole absorber, model UV-328, accounting for 0.8% of the total, which improves the weather resistance of the product for the exposed part. Tinuvin 770DF is selected as the light stabilizer to inhibit photooxidation reaction, accounting for 0.8%. The antioxidant model is 1010 to prevent PP from long-term oxidation and aging, and the overall material accounts for 1.2%. The lubricant (calcium stearate) accounts for 0.2% of the overall material, which reduces the friction between the material and the processing equipment and makes the extrusion smoother.

[0054] Preferably, the reinforcing layer is used to increase the overall structural strength of the packaging material, and homopolymer polypropylene (PP-H) is selected as the main material of the product, accounting for 63%, and the MFR is 15g / 10min, so that the PP resin can be better mixed and infiltrated with the glass fiber during processing. Glass fiber is the key component for reinforcing PP, accounting for 35% of the whole. Glass fiber bundles with a diameter of 30um are selected to greatly enhance the overall strength. The silane coupling agent is γ-aminopropyl triethoxysilane (KH-550), which improves the interfacial bonding between glass fiber and PP, accounting for 1% of the whole. The antioxidant is 1010, which prevents oxidative degradation during PP processing and use, accounting for 0.5% of the total. The lubricant (calcium stearate) accounts for 0.5% of the overall material to reduce the friction between the material and the processing equipment.

[0055] Preferably, as the adhesive layer of the photovoltaic module encapsulation material, copolymer polypropylene (PP-R) is selected as the main material of the product, accounting for 73%, and the melt flow rate is selected as MFR of 5g / 10min to ensure the fluidity and uniformity of the extrusion process. Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total. The compatibilizer can effectively improve the interfacial bonding between the adhesive layer and the reinforcement layer and the weather-resistant layer, and reduce the risk of delamination caused by factors such as polarity differences in different layers of materials. Acrylic tackifiers account for 10% of the total. It has excellent adhesion properties to common photovoltaic module encapsulation materials such as EVA (ethylene-vinyl acetate copolymer), is tightly adsorbed on the surface of the encapsulation material, and greatly improves the peel strength of the adhesive layer. Tinuvin 770DF is selected as a light stabilizer to inhibit photo-oxidation reactions, accounting for 0.8%. The antioxidant model is 1010 to prevent PP from oxidative aging due to long-term use, and the material accounts for 1.2% of the total.

[0056] Step 1:

[0057] Mixing stage: First, put the accurately weighed homopolymer polypropylene and talcum powder into a high-speed mixer in proportion. Set the mixer speed to 800rpm and the mixing time to 10 minutes to fully blend the two. Transfer the pre-mixed materials to the internal mixer at 180℃ for 10 minutes to further fully blend the two materials. Then add light stabilizers, antioxidants and lubricants to complete the mixing process.

[0058] Granulation: Use a twin-screw extruder at a temperature of 170°C, a diameter of 3mm, and a speed of 30rpm to complete uniform granulation.

[0059] Cast film: The screw of the cast film machine adopts a gradual screw to ensure that the material is fully melted. The barrel temperature is set to 190℃, 210℃, and 250℃ in three areas from the hopper to the head, respectively, to ensure that the material has good fluidity during the extrusion process. The cooling roller is controlled at 30℃ to ensure the convenience of winding and produce a weather-resistant layer for the packaging material.

[0060] Step 2: As the reinforcement layer of the packaging material, a certain proportion of coupling agent, lubricant and other additives are first added to the homopolymer polypropylene for mixing and granulation, and then hot melt flows into the specific groove of the processing equipment. The glass fiber is combed neatly by a carding machine, and enters the groove filled with PP through the feeding roller, cylinder, working roller and other components to ensure that the glass fiber is fully impregnated. The design of the groove can make the glass fiber more evenly impregnated with PP, thereby improving the uniformity and density to ensure stability and reliability during use. Four layers are stacked vertically and horizontally for hot machine pre-pressing and shaping to form a plate. The temperature of the plate press is 170℃ and the pressure is 0.1mp. The four-layer vertical and horizontal stacking method not only enhances the strength of the overall back plate, but also ensures that the component has almost zero shrinkage in an environment with a large difference in temperature.

[0061] Step 3:

[0062] Mixing stage: First, accurately weigh the modified PP resin and the maleic anhydride grafted modified PP compatibilizer in proportion into a high-speed mixer. The mixer speed is set at 1000rpm, and the mixing time is 10 minutes to fully blend the two. The pre-mixed materials are transferred to the internal mixer at 200℃ for 15 minutes to further fully blend the two materials. Then, tackifiers and antioxidants are added to complete the mixing process.

[0063] Granulation: Use a twin-screw extruder at a temperature of 170°C, a diameter of 3mm, and a speed of 30rpm to complete uniform granulation.

[0064] Cast film: The screw of the cast film machine adopts a gradual screw to ensure that the material is fully melted. The barrel temperature is set to 190℃, 210℃, and 230℃ in three areas from the hopper to the die head, respectively, to ensure that the material has good fluidity during the extrusion process. The cooling roller is controlled at 30℃ to ensure the convenience of winding.

[0065] Step 4: Full hot pressing. After completing all the sample preparation steps, the weather-resistant layer, the reinforcement layer, and the adhesive layer are stacked from top to bottom, and a high-strength back plate material is formed through comprehensive heat treatment and curing. Preferably, this step adopts hot pressing technology, the hot pressing temperature is 170°C, the heat treatment time is 5 minutes, and the lamination pressure is 0.1mPa. Preferably, a hot press is used to heat and test the material at a constant temperature and pressure. As time goes by, the molecular chains of each layer are more closely connected together to form a dense structure. This step not only improves the overall strength and flatness of the packaging material, but also improves its comprehensive properties such as weather resistance, heat resistance, and chemical resistance, so that the material can fully exert its performance characteristics. The component packaging material that has finally been treated with hot pressing will present excellent appearance quality and outstanding performance.

[0066] Embodiment 2:

[0067] In this embodiment 2, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the resin material is PE.

[0068] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0069] Weathering layer membrane includes the following components:

[0070] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 13% of the total.

[0071] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.8% of the total.

[0072] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0073] The antioxidant model is 1010, accounting for 1.2% of the total.

[0074] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0075] The rest is PE resin.

[0076] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0077] The reinforcement layer includes the following components:

[0078] Glass fiber accounts for 35% of the total.

[0079] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0080] Antioxidant 1010 accounts for 0.2% of the total.

[0081] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0082] The rest is PE resin.

[0083] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0084] The adhesive layer film includes the following components:

[0085] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0086] Acrylic tackifiers account for 10% of the total.

[0087] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0088] The antioxidant model is 1010, accounting for 1.2%.

[0089] The rest is PE resin.

[0090] The preparation method is the same as that of Example 1 above.

[0091] Embodiment 3:

[0092] In this embodiment 3, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the modified resin is PVC.

[0093] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0094] Weathering layer membrane includes the following components:

[0095] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 13% of the total.

[0096] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.8% of the total.

[0097] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0098] The antioxidant model is 1010, accounting for 1.2% of the total.

[0099] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0100] The rest is PVC resin.

[0101] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0102] The reinforcement layer includes the following components:

[0103] Glass fiber accounts for 35% of the total.

[0104] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0105] Antioxidant 1010 accounts for 0.2% of the total.

[0106] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0107] The rest is PVC resin.

[0108] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0109] The adhesive layer film includes the following components:

[0110] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0111] Acrylic tackifiers account for 13% of the total.

[0112] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0113] The antioxidant model is 1010, accounting for 1.2%.

[0114] The rest is PVC resin.

[0115] The preparation method is the same as that of Example 1 above.

[0116] Embodiment 4:

[0117] In this embodiment 4, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the modified resin is ABS.

[0118] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0119] Weathering layer membrane includes the following components:

[0120] The talcum powder model is 800 mesh with a particle size of 10um and a total proportion of 10%.

[0121] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.5% of the total.

[0122] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0123] The antioxidant model is 1010 and accounts for 1% of the total.

[0124] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0125] The rest is ABS resin.

[0126] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0127] The reinforcement layer includes the following components:

[0128] Glass fiber accounts for 35% of the total.

[0129] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0130] Antioxidant 1010 accounts for 0.5% of the total.

[0131] Lubricant (calcium stearate) accounts for 0.5% of the total material.

[0132] The rest is ABS resin.

[0133] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0134] The adhesive layer film includes the following components:

[0135] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 20% of the total.

[0136] Acrylic tackifiers account for 15% of the total.

[0137] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0138] The antioxidant model is 1010, accounting for 1.2%.

[0139] The rest is ABS resin.

[0140] The preparation method is the same as that of Example 1 above.

[0141] Embodiment 5:

[0142] In this embodiment 5, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the modified resin is PMMA.

[0143] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0144] Weathering layer membrane includes the following components:

[0145] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 12% of the total.

[0146] The UV absorber is a benzotriazole absorber, model number is UV-328, accounting for 1% of the total.

[0147] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.6%.

[0148] The antioxidant model is 1010 and accounts for 1% of the total.

[0149] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0150] The rest is PMMA resin.

[0151] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0152] The reinforcement layer includes the following components:

[0153] Glass fiber accounts for 30% of the total.

[0154] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1.2% of the total.

[0155] Antioxidant 1010 accounts for 0.3% of the total.

[0156] Lubricant (calcium stearate) accounts for 0.5% of the total material.

[0157] The rest is PMMA resin.

[0158] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0159] The adhesive layer film includes the following components:

[0160] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0161] Acrylic tackifiers account for 20% of the total.

[0162] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0163] The antioxidant model is 1010 and accounts for 1%.

[0164] The rest is PMMA resin.

[0165] The preparation method is the same as that of Example 1 above.

[0166] Embodiment 6:

[0167] In this embodiment 6, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin bonding layer, wherein the resin is PE.

[0168] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0169] Weathering layer membrane includes the following components:

[0170] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 13% of the total.

[0171] The UV absorber is a benzotriazole absorber, model number is UV-328, accounting for 1% of the total.

[0172] Tinuvin 770DF is selected as the light stabilizer, accounting for 1%.

[0173] The antioxidant model is 1010, accounting for 1.2% of the total.

[0174] Lubricant (calcium stearate) accounts for 0.3% of the total material.

[0175] The rest is PE resin.

[0176] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0177] The reinforcement layer includes the following components:

[0178] Glass fiber accounts for 25% of the total.

[0179] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0180] Antioxidant 1010 accounts for 0.2% of the total.

[0181] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0182] The rest is PE resin.

[0183] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0184] The adhesive layer film includes the following components:

[0185] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0186] Acrylic tackifiers account for 15% of the total.

[0187] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0188] The antioxidant model is 1010, accounting for 1.2%.

[0189] The rest is PE resin.

[0190] The preparation method is the same as that of Example 1 above.

[0191] Embodiment 7:

[0192] In this embodiment 7, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the resin is PVC.

[0193] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0194] Weathering layer membrane includes the following components:

[0195] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 11% of the total.

[0196] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.8% of the total.

[0197] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.5%.

[0198] The antioxidant model is 1010 and accounts for 1% of the total.

[0199] Lubricant (calcium stearate) accounts for 0.5% of the total material.

[0200] The rest is PVC resin.

[0201] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0202] The reinforcement layer includes the following components:

[0203] Glass fiber accounts for 20% of the total.

[0204] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0205] Antioxidant 1010 accounts for 0.2% of the total.

[0206] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0207] The rest is PVC resin.

[0208] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0209] The adhesive layer film includes the following components:

[0210] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0211] Acrylic tackifiers account for 20% of the total.

[0212] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.3%.

[0213] The antioxidant model is 1010, accounting for 0.5%.

[0214] The rest is PVC resin.

[0215] The preparation method is the same as that of Example 1 above.

[0216] Embodiment 8:

[0217] In this embodiment 8, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the resin is ABS.

[0218] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0219] Weathering layer membrane includes the following components:

[0220] The talcum powder model is 800 mesh with a particle size of 10um, accounting for 13% of the total.

[0221] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.8% of the total.

[0222] Tinuvin 770DF is selected as the light stabilizer, accounting for 1%.

[0223] The antioxidant model is 1010, accounting for 1.2% of the total.

[0224] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0225] The rest is ABS resin.

[0226] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0227] The reinforcement layer includes the following components:

[0228] Glass fiber accounts for 35% of the total.

[0229] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 1% of the total.

[0230] Antioxidant 1010 accounts for 0.2% of the total.

[0231] Lubricant (calcium stearate) accounts for 0.8% of the total material.

[0232] The rest is ABS resin.

[0233] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0234] The adhesive layer film includes the following components:

[0235] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0236] Acrylic tackifiers account for 15% of the total.

[0237] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.5%.

[0238] The antioxidant model is 1010, accounting for 1.2%.

[0239] The rest is ABS resin.

[0240] The preparation method is the same as that of Example 1 above.

[0241] Embodiment 9:

[0242] In this embodiment 9, the packaging material structure includes a modified resin weather-resistant layer, a resin glass fiber reinforcement layer, and a modified resin adhesive layer, wherein the resin is PMMA.

[0243] 1) The weather-resistant layer film material is formed through the production process of mixing, granulation and casting.

[0244] Weathering layer membrane includes the following components:

[0245] The talcum powder model is 800 mesh with a particle size of 10um and a total proportion of 10%.

[0246] The UV absorber is a benzotriazole absorber, model UV-328, accounting for 0.2% of the total.

[0247] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.5%.

[0248] The antioxidant model is 1010, accounting for 1.2% of the total.

[0249] Lubricant (calcium stearate) accounts for 0.2% of the total material.

[0250] The rest is PMMA resin.

[0251] 2) The reinforcement layer board is formed through the production process of mixing, granulation, pre-impregnation of glass fiber, and hot pressing.

[0252] The reinforcement layer includes the following components:

[0253] Glass fiber accounts for 30% of the total.

[0254] The silane coupling agent is γ-aminopropyltriethoxysilane (KH-550), accounting for 0.8% of the total.

[0255] Antioxidant 1010 accounts for 0.2% of the total.

[0256] Lubricant (calcium stearate) accounts for 0.5% of the total material.

[0257] The rest is PMMA resin.

[0258] 3) The bonding layer film material is formed through the production process of mixing, granulation and casting.

[0259] The adhesive layer film includes the following components:

[0260] Maleic anhydride grafted modified PP is used as a compatibilizer, accounting for 15% of the total.

[0261] Acrylic tackifiers account for 18% of the total.

[0262] Tinuvin 770DF is selected as the light stabilizer, accounting for 0.8%.

[0263] The antioxidant model is 1010 and accounts for 1%.

[0264] The rest is PMMA resin.

[0265] The preparation method is the same as that of Example 1 above.

[0266] Embodiment 10:

[0267] Preparation of an N-TOPCon cell module using the adhesive film in Example 1

[0268] On the photovoltaic glass (2272*1128*2mm), a layer of POE film dedicated to N-TopCon batteries is laid, and then a square array of N-TopCon battery strings welded in series and parallel is laid, and then another layer of POE film dedicated to N-TopCon batteries is laid, and finally a layer of packaging material for lightweight components described in the above Example 1 is laid to prepare a laminated component using the packaging material.

[0269] The above-mentioned stacked assembly is placed in a laminator for lamination, the lamination temperature is 145°C, the vacuum is drawn for 300s, the segmented lamination pressure is -70kpa, -50kpa, -30kpa, and the lamination time is 600s. After the lamination is completed, a laminated assembly using the packaging material is prepared.

[0270] The laminated assembly is framed and fixed using a photovoltaic aluminum frame (2272*1128*30 mm), and finally a lightweight photovoltaic assembly using the packaging material is prepared.

[0271] Embodiment 11:

[0272] Preparation of a heterojunction cell assembly using the adhesive film in Example 1

[0273] On the photovoltaic glass (2272*1128*2mm), a layer of POE film is laid, followed by laying a square array of heterojunction battery strings welded in series and parallel, and then another layer of POE film is laid, and finally a layer of packaging material for lightweight photovoltaic modules pressed according to the method described in the above Example 1 is laid to prepare a laminated module using the packaging material.

[0274] The above-mentioned stacked assembly is placed in a laminator for lamination, the lamination temperature is 145°C, the vacuum is drawn for 300s, the segmented lamination pressure is -70kpa, -50kpa, -30kpa, and the lamination time is 600s. After the lamination is completed, a laminated assembly using the packaging material is prepared.

[0275] The laminated assembly is framed and fixed using a photovoltaic aluminum frame (2272*1128*30 mm), and finally a lightweight photovoltaic assembly using the packaging material is prepared.

[0276] Embodiment 12:

[0277] Preparation of a perovskite laminated cell module using the adhesive film in Example 1

[0278] On the photovoltaic glass (2272*1128*2mm), a layer of POE film is laid, followed by laying a square array of perovskite laminated battery strings welded in series and parallel, and then another layer of POE film is laid, and finally a layer of packaging material for lightweight photovoltaic modules pressed according to the method described in the above Example 1 is laid to prepare a laminated module using the packaging material.

[0279] The above-mentioned stacked assembly is placed in a laminator for lamination, the lamination temperature is 145°C, the vacuum is drawn for 300s, the segmented lamination pressure is -70kpa, -50kpa, -30kpa, and the lamination time is 600s. After the lamination is completed, a laminated assembly using the packaging material is prepared.

[0280] The laminated assembly is framed and fixed using a photovoltaic aluminum frame (2272*1128*30 mm), and finally a lightweight photovoltaic assembly using the packaging material is prepared.

[0281] Comparative Example 1:

[0282] The following packaging materials are pressed according to patent CN 116487460A

[0283] (1) Thermosetting powder resin is evenly coated on the glass fiber cloth through a powder spreading device, or the glass fiber is soaked in thermosetting liquid resin.

[0284] (2) Pre-curing and bonding of the resin and glass fiber and volatilization of the solvent are achieved by pressurized heating or hot baking.

[0285] (3) After the above step (2) is completed, a hot press is used to perform secondary curing and molding by heating and pressurizing;

[0286] (4) After completing the above step (3), the surface tension is increased by corona or plasma technology.

[0287] (5) After completing the above step (4), a coating of the rear plate reinforcement layer is applied.

[0288] (6) After the above step (5) is completed, heat-drying, dividing and cutting are performed.

[0289] (7) Obtaining lightweight packaging materials for photovoltaic modules.

[0290] Comparative Example 2:

[0291] This comparative example 2 is the most common packaging material for lightweight components in the current photovoltaic market, that is, the aluminum back panel is directly used as the packaging back panel of the lightweight component.

[0292] Comparative Example 3:

[0293] Preparation of an N-TopCon battery assembly using the packaging material in Comparative Example 1

[0294] On the photovoltaic glass (2272*1128*2mm), a layer of POE film dedicated to N-TopCon batteries is laid, and then a square array of N-TopCon battery strings welded in series and parallel is laid, and then another layer of POE film dedicated to N-TopCon batteries is laid, and finally a layer of packaging material for lightweight photovoltaic modules pressed according to patent CN 116487460A is laid to prepare a laminated module using the packaging material.

[0295] The above-mentioned stacked assembly is placed in a laminator for lamination, the lamination temperature is 145°C, the vacuum is drawn for 300s, the segmented lamination pressure is -70kpa, -50kpa, -30kpa, and the lamination time is 600s. After the lamination is completed, a laminated assembly using the packaging material is prepared.

[0296] The laminated assembly is framed and fixed using a photovoltaic aluminum frame (2272*1128*30 mm), and finally a lightweight photovoltaic assembly using the packaging material is prepared.

[0297] The evaluation method is as follows:

[0298] Evaluation of packaging material hardness

[0299] The surface hardness and wear resistance of the packaging material were tested using a pencil hardness tester and a falling sand test.

[0300] Tensile evaluation of packaging materials.

[0301] Use a tensile testing machine to test the tensile strength of the product.

[0302] Evaluation of components

[0303] Power attenuation after testing the DH1000 module.

[0304] The results are as follows:

[0305]

[0306] Result analysis:

[0307] Due to the advanced nature of the technical solution, it can be widely used in the fields of photovoltaic power generation equipment manufacturing, building-integrated photovoltaic systems, outdoor advertising displays, etc. First, the packaging material of the present invention has the characteristics of high production efficiency and low energy consumption, which can greatly improve the production efficiency of photovoltaic modules, reduce production costs, and meet the needs of photovoltaic power generation equipment manufacturers for high efficiency and low cost. Secondly, the packaging material of the present invention has high strength, high adhesion, and aging resistance. It can effectively protect photovoltaic cells, improve the durability and impact resistance of photovoltaic modules, extend the service life of cells, and meet the high reliability requirements of photovoltaic modules in the fields of building-integrated photovoltaic systems and outdoor advertising displays. Finally, the packaging material of the present invention has the characteristics of light weight, which can reduce the weight of photovoltaic modules, facilitate installation and transportation, and meet the needs of photovoltaic power generation equipment manufacturers for lightweight products.

[0308] By comparing Examples 1-9 with Comparative Examples 1 and 2, it is found that the hardness, wear resistance and tensile strength of the lightweight photovoltaic module packaging material pressed by the present invention are much better than the lightweight photovoltaic module packaging material currently used in the market.

[0309] By comparing Examples 1-9 with Comparative Example 1, it is found that the packaging material of the present invention has better wear resistance and adhesion than existing photovoltaic packaging materials on the market after using modified PP.

[0310] Comparing Examples 10-12 with Comparative Example 3, it is found that the light-weight components made of the packaging material prepared by the present invention have a smaller attenuation than the initial power after DH1000 test, which indicates that the water-blocking performance of the components is greatly improved by using the packaging material of the present invention.

[0311] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A lightweight photovoltaic module back plate packaging material, characterized in that: The rear panel packaging material is composed of a modified resin weather-resistant layer, a resin fiber reinforcement layer, and a modified resin bonding layer from top to bottom; The modified resin bonding layer accounts for 5%-30% of the weight of the rear plate; The resin fiber reinforcement layer accounts for 40%-90% of the weight of the rear plate; The modified resin weather-resistant layer accounts for 5%-30% of the weight of the rear plate.

2. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The modified resin bonding layer comprises the following components: resin as the main component, accounting for 60%-70%; Maleic anhydride grafted modified PP is used as a compatibilizer, with a content of 15% to 20%; Acrylate tackifier, content is 10% to 20%; Add appropriate amount of antioxidant 0.5%-1.5% and light stabilizer 0.3%~0.8%.

3. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The resin fiber reinforced layer includes the following components: resin as the main component, accounting for 60% to 90%, Glass fiber is a reinforcing material, and its content accounts for 10% to 40% of the total. The additive composition includes the following components: 0.5%-2% of coupling agent, 0.1%-0.5% of antioxidant, and 0.3%-0.8% of lubricant.

4. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The modified resin weather-resistant layer comprises the following components, with the resin as the main material accounting for 70%-90%; UV absorber 0.1%-1%, Light stabilizer 0.5%-1%, Antioxidants 0.5%-1.2%, Talc 10%-15%, Lubricant 0.2%~0.5%.

5. The lightweight photovoltaic module back sheet encapsulation material according to claim 1, characterized in that: The resins in the modified resin weather-resistant layer, the resin fiber reinforced layer, and the modified resin adhesive layer are respectively one or more of polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), ABS resin, polycarbonate (PC), polyamide (nylon), polyphenylene ether (PPO), polyurethane (PU), polyester (PET, PBT), and PMMA, and the resins in the modified resin weather-resistant layer, the resin fiber reinforced layer, and the modified resin adhesive layer may be the same or different.

6. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The thickness of the modified resin bonding layer material ranges from 100 to 2000 μm; The thickness of the modified resin weather-resistant layer material ranges from 100 to 2000 μm; The thickness of the resin fiber reinforced layer material ranges from 900 to 3000 μm.

7. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The modified resin bonding layer material has an adhesion of POE or EVA of ≥100N / cm.

8. The lightweight photovoltaic module back sheet packaging material according to claim 1, characterized in that: The modified resin bonding layer material has a visible light reflectivity of ≥90%.

9. A method for preparing a lightweight photovoltaic module back panel packaging material, characterized in that: The following steps are involved: The adhesive layer and the weather-resistant layer are extruded by a screw extruder; a reinforcing layer is sandwiched between the weather-resistant layer and the adhesive layer; and the composite three-layer structure is laminated by a hot press to obtain the photovoltaic back panel; The thermal compounding temperature is ≥165° C., and the thermal compounding pressure is 0.1-1 mPa.

10. A method for preparing a lightweight photovoltaic module, characterized in that: The following steps are involved: On the photovoltaic glass, a layer of POE film is laid flat, followed by laying a battery string array, and then another layer of POE film is laid flat, and finally a layer of the lightweight photovoltaic module back panel packaging material according to claim 1 is laid flat, to prepare a laminated module using the packaging material; The stacked components are placed in a laminator for lamination, and the lamination is performed in sections. After the lamination is completed, a laminated component using the packaging material is prepared; The laminated assembly is framed and fixed with a photovoltaic aluminum frame, and finally a lightweight photovoltaic assembly using the packaging material is prepared.

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