Composite material for front plate of light component and preparation method of composite material

Abstract

The invention relates to a composite material for a front plate of a light component, which comprises glass fiber cloth and a liquid polyurethane acrylate coating, and the glass fiber cloth is uniformly coated with the liquid polyurethane acrylate coating; the glass fiber cloth is prepared from the following components in parts by weight: 30 to 70 parts of glass fiber cloth and 50 to 70 parts of liquid polyurethane acrylate coating. The preparation method of the composite material for the front plate of the light component comprises the following steps: uniformly coating the glass fiber cloth with a liquid polyurethane acrylate coating, and carrying out preliminary impregnation to prepare a prepreg; the prepreg is heated and subjected to vacuum curing by adopting laminating or mold pressing equipment, so that the resin fully infiltrates the glass fiber cloth and is molded to prepare a composite material; and cutting the composite material according to the required size to obtain the photovoltaic module front plate. The method not only effectively overcomes the defects of high processing temperature, long processing time and the like of the existing light component front plate, but also has the advantages of high light transmittance, good weather resistance, high hardness and the like.

Description

TECHNICAL FIELD

[0001] The present application relates to a composite material and a preparation method, in particular to a composite material and a preparation method for a front plate of a light-weight assembly, wherein the prepared front plate has the characteristics of light weight, high light transmittance, good weather resistance and high hardness. BACKGROUND

[0002] As a clean energy core track, the installed capacity of photovoltaic power generation continues to grow (according to the data of the International Renewable Energy Agency, the global cumulative installed capacity of photovoltaic power generation is expected to exceed 2500GW in 2025); a traditional photovoltaic assembly is composed of glass, adhesive film, cell piece, back plate and frame, but the weight bottleneck of the traditional photovoltaic assembly gradually becomes a key factor limiting the expansion of application scenarios; roof photovoltaic accounts for more than 40% of global new installations, but the traditional photovoltaic assembly has high requirements for roof load, especially high energy-consuming enterprises (such as steelmaking, textile and food industry) usually adopt light steel structure roof, and excessive weight increases the safety risk of building load; mobile energy and special scenarios develop rapidly, and vehicle-mounted photovoltaic, unmanned aerial vehicle and airship-mounted photovoltaic require the weight of the assembly to be ≤5kg / ㎡ (the weight of the traditional assembly is about 12-15kg / ㎡), otherwise the power generation gain is offset or even affects the normal use of the equipment;

[0003] The weight of the assembly mainly comes from the front plate glass (about 70%), and the light-weight assembly refers to the use of light-weight materials to replace glass, and the replacement materials of traditional glass need to meet the requirements of high light transmittance, weather resistance and impact resistance;

[0004] At present, some technical solutions are used to replace traditional tempered glass to produce light-weight assemblies, such as PET film, etc., but these materials are difficult to meet the requirements in terms of impact resistance, weather resistance and dimensional stability;

[0005] Some technical solutions also disclose a composite material for light-weight assembly, such as the invention patent with publication number CN108589319B discloses an encapsulating material for photovoltaic assembly, but the powder coating used by it has high requirements for equipment in the processing process, and the powder coating needs to be heated and solidified, which has high energy consumption and low hardness and weak rigidity; therefore, it is necessary to develop a light-weight assembly front plate with high efficiency, no pollution and mild processing mode. SUMMARY

[0006] In view of the above problems, the main purpose of the present application is to provide a composite material and a preparation method for a light-weight assembly front plate, wherein the prepared front plate has the characteristics of light weight, high light transmittance, good weather resistance and high hardness.

[0007] The present application is to solve the above technical problems by the following technical solutions: a composite material for a light component front plate, comprising a glass fiber cloth and a liquid polyurethane acrylate coating, the liquid polyurethane acrylate coating is uniformly coated on the glass fiber cloth; the glass fiber cloth is 30-70 parts by weight, and the liquid polyurethane acrylate coating is 50-70 parts by weight.

[0008] In a specific embodiment of the present application, the glass fiber cloth is woven by glass fiber yarn, the unit area weight is 50-400 g / m2, the refractive index is 1.40-1.55, and any one of plain weave, twill weave and satin weave is woven.

[0009] In a specific embodiment of the present application, the liquid polyurethane acrylate coating comprises the following components with the following weight content: polyurethane acrylate resin 80-100 parts, initiator 0-10 parts, antioxidant 0-2 parts, light stabilizer 0-2 parts, and ultraviolet absorber 0-2 parts.

[0010] In a specific embodiment of the present application, the polyurethane acrylate resin belongs to an unsaturated resin system, the functionality range is 2-4, and the viscosity range is 50-150 Pa·s / 30℃.

[0011] In a specific embodiment of the present application, the initiator is any one or a combination of the following: 2-ethylhexanoic acid tert-butyl peroxide, tert-amyl peroxy acetate, di-tert-amyl peroxide, tert-butyl peroxy benzoate, tert-amyl peroxy benzoate, di-tert-butyl peroxide, di-tert-amyl peroxide, and 2,5-dimethyl-2,5-di-tert-butylperoxy ethane.

[0012] In a specific embodiment of the present application, the antioxidant is any one or a combination of the following: hindered phenol, amine compound, phosphite, and thioester.

[0013] In a specific embodiment of the present application, the light stabilizer is a hindered amine light stabilizer, and the ultraviolet absorber is a triazine.

[0014] A preparation method of the above-mentioned composite material for a light component front plate, the preparation method comprising the following steps:

[0015] Step 1: uniformly coating the liquid polyurethane acrylate coating on the glass fiber cloth to preliminarily impregnate and prepare a prepreg.

[0016] Step 2: using a laminating or molding device to vacuum and heat cure the prepreg to make the resin fully impregnate the glass fiber cloth and form a composite material.

[0017] Step 3: cutting the composite material according to the required size to obtain a photovoltaic component front plate.

[0018] In the specific embodiment of the present application, the liquid polyurethane acrylate coating is coated on the glass fiber cloth by coating or impregnation, the coating method is hot melt knife coating or hot melt roll coating, and the impregnation method is hot melt impregnation.

[0019] In the specific embodiment of the present application, the heating and curing temperature is 100-150℃, the pressure is 0.05-10MPa, and the time is 5-15min.

[0020] The positive progress effect of the present application is that the composite material for the front plate of a lightweight assembly and the preparation method have the following advantages: the present application provides a way of using liquid resin to process prepreg to prepare a composite material for the front plate of a lightweight assembly, which not only effectively solves the problems of high processing temperature and long processing time of the existing lightweight assembly front plate, but also has the advantages of high light transmittance, good weather resistance and high hardness. DETAILED DESCRIPTION

[0021] The preferred embodiment of the present application is given below to explain the technical scheme of the present application in detail.

[0022] The embodiment of the present application discloses a composite material for the front plate of a lightweight assembly for a photovoltaic lightweight assembly front plate material, which comprises uniformly coating 50-70 parts of liquid polyurethane acrylate coating on 30-70 parts of glass fiber cloth and hot pressing to form; the preparation method provides a new way of producing a lightweight assembly front plate, which has a significantly reduced weight, high light transmittance, and good mechanical strength and aging resistance; at the same time, it has the characteristics of rapid forming, low energy consumption, and convenient installation.

[0023] The prepared lightweight assembly front plate specifically comprises uniformly coating 30-70 parts of liquid polyurethane acrylate coating on 50-70 parts of glass fiber cloth to form a prepreg, cutting the prepreg according to the size of the lightweight assembly, and curing the cut prepreg by lamination or molding process to form a composite material for a photovoltaic lightweight assembly front plate.

[0024] In the present application, the glass fiber cloth is woven from glass fiber yarn, the weight per unit area is 50-400g / m2, the refractive index is 1.40-1.55, and it is woven by any one of plain weave, twill weave, and satin weave.

[0025] In the present application, the liquid polyurethane acrylate coating comprises the following components with the following weight contents: polyurethane acrylate resin 80-100 parts, initiator 0-10 parts, antioxidant 0-2 parts, light stabilizer 0-2 parts, and ultraviolet absorber 0-2 parts.

[0026] The polyurethane acrylate resin in the application belongs to an unsaturated resin system, the functionality ranges from 2 to 4, and the viscosity ranges from 50 to 150 Pa·s / 30 DEG C.

[0027] The initiator in the application is any one or a combination of several of 2-ethylhexyl acid tert-butyl peroxide, tert-amyl peroxy acetate, di-tert-amyl peroxide, tert-butyl peroxy benzoate, tert-amyl peroxy benzoate, di-tert-butyl peroxide, di-tert-amyl peroxide, 2,5 dimethyl-2,5-di-tert-butylperoxy ethane.

[0028] The antioxidant in the application is any one or a combination of several of a hindered phenol, an amine compound, a phosphite, and a thioester.

[0029] The light stabilizer in the application is a hindered amine light stabilizer, and the ultraviolet absorber is a triazine.

[0030] The application further provides a preparation method of the composite material for the front plate of the lightweight assembly.

[0031] Step 1: uniformly coating the liquid polyurethane acrylate coating on the glass fiber cloth to preliminarily impregnate to prepare a prepreg; in the application, the coating or impregnation is used to coat the liquid polyurethane acrylate coating on the glass fiber cloth, the coating method is hot melt blade coating or hot melt roller coating, and the impregnation method is hot melt impregnation.

[0032] Step 2: vacuum and heating curing of the prepreg by using a laminating or molding device to make the resin fully impregnate the glass fiber cloth and form the composite material; in the application, the heating curing temperature is 100-150 DEG C, the pressure is 0.05-10 MPa, and the time is 5-15 min.

[0033] Step 3: cutting the composite material according to the required size to obtain the front plate of the photovoltaic assembly.

[0034] The application is a new way of producing the front plate of the lightweight assembly, the weight is significantly reduced, the light transmittance is high, and the mechanical strength and the anti-aging performance are good; meanwhile, the application has the characteristics of rapid forming, low energy consumption, and convenient installation.

[0035] To more clearly show the technical scheme of the application, the following will be completely described through embodiments; obviously, the described embodiments are only some of the embodiments of the application, but not all the embodiments, and for those skilled in the art, other embodiments can be obtained according to the application without creative labor, which all belong to the protection scope of the application.

[0036] Embodiment 1

[0037] A light-weight photovoltaic module front sheet comprising the following raw materials in the following weight fractions:

[0038] 30 to 70 parts of a glass fiber cloth, which is a glass fiber cloth woven using glass fiber yarns, for providing dimensional stability, insulation, and mechanical properties required for a light-weight module front sheet;

[0039] Preferably, the glass fiber cloth has a weight per unit area of 60 to 400 g / m2, and specifically, 60 g / m2, 80 g / m2, 100 g / m2, 160 g / m2, 200 g / m2, or 400 g / m2. In the present embodiment, the glass fiber cloth has a weight per unit area of 80 g / m2.

[0040] Preferably, the glass fiber cloth is woven using any one of plain weave, twill weave, satin weave, or the like in the present embodiment. In the present embodiment, the glass fiber cloth is woven using plain weave. 30 to 70 parts of a liquid polyurethane acrylate coating, which is a liquid coating for providing good processability of the coating, and the polyurethane acrylate provides good weather resistance. In the present embodiment, the weight per unit area of the selected liquid polyurethane acrylate coating is controlled to be 100 g / m2.

[0041] Preferably, the polyurethane acrylate coating includes the following raw materials in the following weight fractions: 80 to 100 parts of a polyurethane acrylate resin; 0 to 10 parts of an initiator; 0 to 2 parts of an antioxidant; 0 to 2 parts of a light stabilizer; and 0 to 2 parts of an ultraviolet absorber. In the present embodiment, the liquid polyurethane acrylate coating includes 96.5 parts of a liquid polyurethane acrylate resin, 1 part of an initiator, 1 part of an antioxidant, 0.5 parts of a light stabilizer, and 1 part of an ultraviolet absorber.

[0042] Preferably, the polyurethane acrylate resin belongs to an unsaturated resin system, has a functionality in the range of 2 to 4, and has a viscosity in the range of 50 to 150 Pa·s / 30℃. In the present embodiment, the polyurethane acrylate has a functionality of 2.7 and a viscosity of 110 Pa·s / 30℃.

[0043] Preferably, the initiator is any one of or a combination of 2-ethylhexyl acid tert-butyl peroxide, tert-amyl acid peroxide, di-tert-amyl peroxide, tert-butyl benzene peroxide, tert-amyl benzene peroxide, di-tert-butyl peroxide, di-tert-amyl peroxide, 2,5-dimethyl-2,5-di-tert-butylperoxy ethane. In the present embodiment, the selected initiator is a 1:1 mixture of 2-ethylhexyl acid tert-butyl peroxide and tert-butyl benzene peroxide.

[0044] Preferably, the antioxidant includes any one or a combination of hindered phenols, amine compounds, phosphites, thioesters; the selected antioxidant in this embodiment is a hindered phenolic antioxidant CHINOX 1076.

[0045] Preferably, the light stabilizer is a hindered amine light stabilizer; the selected light stabilizer in this embodiment is a light stabilizer UV-123.

[0046] Preferably, the ultraviolet absorber is a triazine; the selected ultraviolet absorber in this embodiment is a light stabilizer UV-400.

[0047] The mixing method of the liquid polyurethane acrylate coating mentioned in the embodiment of the present application is mixed by using a known coating mixing method, and a typical method is to prepare a liquid polyurethane acrylate resin by heating and reducing the viscosity of the resin in a jacketed stirred tank and stirring; preferably, the temperature in the jacketed stirred tank is controlled at 50-90℃, and the stirring time is 10-40 minutes, and in this embodiment, the stirring tank temperature is 70℃, and the stirring time is 30 minutes.

[0048] The present application provides a preparation method of the light component front plate described in the above technical solution.

[0049] 1. The liquid polyurethane acrylate coating is uniformly coated on the glass fiber cloth to preliminarily impregnate and prepare a prepreg.

[0050] 2. The prepreg is molded into a composite material by using a laminating or molding device to make the resin fully impregnate the glass fiber cloth and form.

[0051] 3. The composite material is cut according to the required size to obtain a photovoltaic component front plate.

[0052] In this embodiment, the method used for uniformly coating the liquid polyurethane acrylate on the glass fiber cloth is hot melt knife coating, the polyurethane acrylate resin coating is uniformly coated on the glass fiber cloth, preferably, the knife gap is controlled to adjust the coating weight per unit area to 100g / ㎡, the hot melt temperature is 50℃, and the coating line speed is 2m / min; after coating, the prepreg is coated with release paper, the prepreg is laminated and cured under the laminating conditions of 150℃ and a pressure of 0.08MPa for 11min, the composite material is obtained after cooling, and the light component front plate is obtained by cutting according to the required size of the light component, the weight per unit area of the light component front plate is 180g / ㎡, and the thickness is 0.13±0.01mm.

[0053] Embodiment 2

[0054] A lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, and had a unit area weight of 160 g / m2, and the selected liquid polyurethane acrylate coating was controlled to have a unit area weight of 240 g / m2; the lightweight assembly front plate had a unit area weight of 400 g / m2, and a thickness of 0.3 mm ± 0.02 mm.

[0055] Example 3

[0056] A lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, and had a unit area weight of 160 g / m2, and the selected liquid polyurethane acrylate coating was controlled to have a unit area weight of 240 g / m2; the lightweight assembly front plate had a unit area weight of 400 g / m2, and a thickness of 0.3 mm ± 0.02 mm.

[0057] Example 4

[0058] A lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, and had a unit area weight of 160 g / m2, and the selected liquid polyurethane acrylate coating was controlled to have a unit area weight of 240 g / m2; the lightweight assembly front plate had a unit area weight of 400 g / m2, and a thickness of 0.3 mm ± 0.02 mm.

[0059] Example 5

[0060] A lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, and had a unit area weight of 160 g / m2, and the selected initiator was di-tert-butyl peroxide, and the selected liquid polyurethane acrylate coating was controlled to have a unit area weight of 330 g / m2; the prepreg was cured under lamination conditions of 155 °C and a pressure of 0.08 MPa for 11 min; the lightweight assembly front plate had a unit area weight of 300 g / m2, and a thickness of 0.4 mm ± 0.03 mm.

[0061] Example 6

[0062] A lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, and had a unit area weight of 160 g / m2, and the selected initiator was di-tert-butyl peroxide, and the selected liquid polyurethane acrylate coating was controlled to have a unit area weight of 330 g / m2; the prepreg was cured under lamination conditions of 155 °C and a pressure of 0.08 MPa for 11 min; the lightweight assembly front plate had a unit area weight of 300 g / m2, and a thickness of 0.4 mm ± 0.03 mm.

[0063] Example 7

[0064] The lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, the unit area weight was 160 g / m2, the initiator selected was di-t-butyl peroxide, the unit area weight of the selected liquid polyurethane acrylate coating was controlled at 140 g / m2, the prepreg was laminated and cured under the lamination conditions of 155°C and a pressure of 0.08 MPa for 11 min; the unit area weight of the lightweight assembly front plate was 300 g / m2, and the thickness was 0.2 mm ± 0.02 mm.

[0065] Example 8

[0066] The lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a twill weave, the unit area weight was 160 g / m2, the initiator selected was di-t-butyl peroxide, the unit area weight of the selected liquid polyurethane acrylate coating was controlled at 140 g / m2, the prepreg was laminated and cured under the lamination conditions of 155°C and a pressure of 0.08 MPa for 11 min; the unit area weight of the lightweight assembly front plate was 300 g / m2, and the thickness was 0.2 mm ± 0.02 mm.

[0067] Example 9

[0068] The lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a satin weave, the unit area weight was 200 g / m2, the initiator selected was di-t-butyl peroxide benzoate, the unit area weight of the selected liquid polyurethane acrylate coating was controlled at 140 g / m2, the prepreg was laminated and cured under the lamination conditions of 150°C and a pressure of 0.08 MPa for 11 min; the unit area weight of the lightweight assembly front plate was 300 g / m2, and the thickness was 0.2 mm ± 0.02 mm.

[0069] Example 10

[0070] The lightweight assembly front plate was prepared according to the method of Example 1, except that in this example the glass fiber cloth used was woven in a satin weave, the unit area weight was 200 g / m2, the initiator selected was di-t-butyl peroxide benzoate, the unit area weight of the selected liquid polyurethane acrylate coating was controlled at 240 g / m2, the prepreg was laminated and cured under the lamination conditions of 150°C and a pressure of 0.08 MPa for 11 min; the unit area weight of the lightweight assembly front plate was 440 g / m2, and the thickness was 0.3 mm ± 0.02 mm.

[0071] Comparative Example 1

[0072] Comparative Example 1 is a commercially available PET film used as a front plate of a lightweight component.

[0073] Comparative Example 2

[0074] Comparative Example 2 is a composite material made of a commercially available epoxy acrylic powder coating and a glass fiber cloth used as a front plate of a lightweight component, and the curing condition is laminated curing at 160℃ under a pressure of 0.08MPa for 20min.

[0075] The present application is tested for the above examples and comparative examples, and the test standards and results are shown in Table 1. The performance of the above examples and comparative examples is characterized, and the results are shown in Table 1.

[0076] The thickness, heat shrinkage, tensile strength are tested according to GB / T13542.2-2009, the heat shrinkage is only listed for the longitudinal direction (MD), the light transmittance is tested according to GB / T2410-2008, and the PCT aging treatment is tested in a PCT aging oven, the test temperature is set to 121℃, the test time is 48h, after the test is completed, the sample is taken out and placed in a dryer for more than 2h after the instrument pressure is displayed as 0MPa and the temperature is reduced to below 80℃ to check the appearance and light transmittance decay of the sample.

[0077] Table 1

[0078]

[0079]

[0080] As can be seen from Table 1, compared with the existing PET technical solution, the present application has lower heat shrinkage, higher tensile strength and lower decay in aging test, etc., and has obvious advantages in aging resistance compared with other commercially available composite materials; the lightweight component front plate made of the polyurethane acrylate coating and the glass fiber cloth has excellent light transmittance, low heat shrinkage, excellent mechanical properties and aging resistance; at the same time, we can see that the same test effect can be achieved after relatively mild curing conditions, which is of great help to reduce energy consumption and improve efficiency.

[0081] The present application not only provides a new way for producing lightweight components, but also has mild processing conditions, low energy consumption and high production efficiency, which is convenient for large-scale development of lightweight components.

[0082] The above shows and describes the basic principles and main features of the present application and the advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above embodiments, and the above embodiments and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A composite material for the front panel of a lightweight component, characterized in that, The composite material used for the front panel of the lightweight component includes fiberglass cloth and liquid polyurethane acrylate coating, wherein the liquid polyurethane acrylate coating is uniformly coated on the fiberglass cloth; by weight fraction, the fiberglass cloth is 30-70 parts and the liquid polyurethane acrylate coating is 50-70 parts.

2. The composite material for the front panel of a lightweight component according to claim 1, characterized in that: The fiberglass cloth is woven from fiberglass yarn, with a unit area weight of 50-400g / ㎡ and a refractive index of 1.40-1.

55. It is woven using any one of the following weaving methods: plain weave, twill weave, or satin weave.

3. The composite material for the front panel of a lightweight component according to claim 1, characterized in that: The liquid polyurethane acrylate coating comprises the following components in the following weight percentages: 80-100 parts polyurethane acrylate resin, 0-10 parts initiator, 0-2 parts antioxidant, 0-2 parts light stabilizer, and 0-2 parts ultraviolet absorber.

4. The composite material for the front panel of a lightweight component according to claim 3, characterized in that: The polyurethane acrylate resin is an unsaturated resin system with a functionality range of 2-4 and a viscosity range of 50-150 Pa·s / 30℃.

5. The composite material for the front panel of a lightweight component according to claim 3, characterized in that: The initiator is any one or a combination of several of the following: tert-butyl peroxyethylhexanoate, tert-amyl peroxyacetate, di-tert-amyl peroxy, tert-butyl peroxybenzoate, di-tert-butyl peroxy, di-tert-amyl peroxy, and 2,5-dimethyl-2,5-di-tert-butyl peroxyethane.

6. The composite material for the front panel of a lightweight component according to claim 3, characterized in that: Antioxidants are any one or a combination of several of hindered phenols, amines, phosphites, and thioesters.

7. The composite material for the front panel of a lightweight component according to claim 3, characterized in that: The light stabilizer is a hindered amine light stabilizer, and the ultraviolet absorber is a triazine.

8. A method for preparing a composite material for a lightweight component front panel according to any one of claims 1-7, characterized in that: The preparation method includes the following steps: Step 1: The liquid polyurethane acrylate coating is uniformly coated onto the glass fiber cloth to initially impregnate it and prepare a prepreg. Step 2: The prepreg is cured by vacuum and heat using lamination or molding equipment to fully impregnate the glass fiber cloth with resin and form it into a composite material; Step 3: Cut the composite material to the required dimensions to obtain the front panel of the photovoltaic module.

9. The method for preparing the composite material for the front panel of a lightweight component according to claim 8, characterized in that: Liquid polyurethane acrylate coating is applied to fiberglass cloth by coating or impregnation. The coating method is hot melt scraping or hot melt roller coating, and the impregnation method is hot melt impregnation.

10. The method for preparing the composite material for the front panel of a lightweight component according to claim 8, characterized in that: The heating and curing temperature is 100-150℃, the pressure is 0.05-10MPa, and the time is 5-15min.

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