Resin-based composite material applied to photovoltaic module and preparation method of resin-based composite material

Abstract

The invention belongs to the technical field of photovoltaic modules, and particularly relates to a resin-based composite material applied to a photovoltaic module and a preparation method of the resin-based composite material. The preparation method of the resin-based composite material comprises the following steps: S1, dispersing a mixture of a cyclic olefin material, a curing agent and a coupling agent to obtain a blend; s2, mixing the blend obtained in the step S1 with fibers, and carrying out pultrusion to obtain a pre-cured molded body; and S3, carrying out secondary processing on the pre-cured molded body obtained in S2 to obtain the composite material. The bending strength, ultraviolet resistance and salt spray corrosion resistance of the composite material prepared by the method provided by the invention are greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module technology, specifically relating to a resin-based composite material for use in photovoltaic modules and its preparation method. Background Technology

[0002] As the core component of a solar power generation system, the performance of photovoltaic (PV) modules directly determines the system's power generation efficiency and lifespan. Currently, PV modules primarily utilize aluminum alloy frames and polyurethane resin-based composite materials, manufactured through a pultrusion process. However, this existing material system and manufacturing process still have many limitations, severely impacting the overall performance and large-scale application of the product.

[0003] In terms of materials, the polyurethane resin used has a high curing temperature, poor corrosion resistance, and is sensitive to water. This necessitates dehumidification of the glass fiber and the factory, resulting in high energy consumption. Furthermore, it requires extremely complex post-processing and spraying to achieve corrosion protection. While existing technologies increase the glass fiber content to improve the composite material's performance, this method leads to poor composite toughness and cracking due to the resin's inherently low toughness.

[0004] At the process level, existing technologies mainly rely on pultrusion molding, which can only produce products with uniform cross-sections. The resins currently used have high viscosity, preventing rapid impregnation of glass fiber filaments through the mold. To achieve sufficient impregnation, the pultrusion speed needs to be reduced significantly, thus affecting molding efficiency and increasing manufacturing costs. Furthermore, to ensure good demolding, large amounts of release agent are often added. Excessive release agent not only affects material properties but also further increases the difficulty and cost of subsequent spraying. On the other hand, existing resin systems are mostly multi-component mixtures, which are prone to foaming after mixing, failing to meet the requirements of single-component injection molding processes.

[0005] Therefore, there is an urgent need to develop a new type of resin-based composite material and its molding process to improve the overall performance and production efficiency of photovoltaic modules. Summary of the Invention

[0006] In view of the above-mentioned problems in the prior art, the present invention provides a method for preparing a resin-based composite material, comprising the following steps: S1. Disperse a mixture of cyclic olefin material, curing agent and silane coupling agent to obtain a blend; S2. The blend obtained in step S1 is mixed with fibers and pultruded to obtain a pre-cured molded body; S3. The pre-cured molded body obtained in S2 is subjected to secondary processing to obtain the composite material.

[0007] In some embodiments, by weight, the cyclic olefin material comprises 5-50 parts, the curing agent 2-30 parts, the coupling agent 0.01-2 parts, and the fiber 40-90 parts.

[0008] In some embodiments, the blend further comprises an additive; in some embodiments, the additive is one or both of a thermosetting resin or a release agent; in some embodiments, the thermosetting resin is selected from one or more of polyester resins, vinyl resins, phenolic resins, epoxy resins, and polyurethanes.

[0009] In some embodiments, the cyclic olefin material is selected from one or more of cyclopentene, dicyclopentadiene, cyclopentadiene, or norbornene; in some embodiments, the cyclic olefin material is selected from one or two of dicyclopentadiene or norbornene.

[0010] In some embodiments, the silane coupling agent is selected from one or more of aminosilane coupling agents, epoxysilane coupling agents, acryloyloxysilane coupling agents, alkylsilane coupling agents, and vinylsilane coupling agents.

[0011] In some embodiments, the fiber is one or more of glass fiber, carbon fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, basalt fiber, and hemp fiber.

[0012] In some embodiments, the dispersion in step S1 is carried out by dispersion stirring or ultrasonic dispersion; in some embodiments, the dispersion stirring is carried out by a high-speed disperser at a speed of 800-1500 rpm; in some embodiments, the dispersion stirring is carried out by a high-speed disperser at a speed of 1200 rpm.

[0013] In some embodiments, the pultrusion process speed in step S2 is 0.1~2 m / min; in some embodiments, the pultrusion process speed is 0.5~1.5 m / min; in some embodiments, the temperature of the pultrusion process is 30~350℃; in some embodiments, the pultrusion process is divided into at least three temperature zones, which are set as follows: Zone 1 40℃~150℃, Zone 2 60℃~280℃, and Zone 3 60℃~320℃.

[0014] In some embodiments, the secondary processing in step S3 includes one or more of compression molding, injection molding, co-extrusion, or pultrusion; in some embodiments, the pressure of the compression molding process is 2-5 MPa; in some embodiments, the pressure of the injection molding process is 2-5 MPa.

[0015] In some embodiments, the secondary processing further includes the step of applying a functional material, such as a corrosion-resistant material or an aging-resistant material, to the surface of the pre-cured molded body.

[0016] In one aspect, the present invention provides a resin-based composite material, which is prepared by the method described above.

[0017] In one aspect, the present invention provides a photovoltaic module comprising the aforementioned resin-based composite material.

[0018] The preparation method provided by this invention uses cyclic olefin materials to prepare photovoltaic modules. It does not require complex curing process conditions and can be prepared by pultrusion. The pultrusion process has a fast pultrusion speed and high molding efficiency, and does not require the addition of a large amount of release agent. Based on the pultrusion molding process, this invention develops a new continuous molding process that combines pultrusion, compression molding, injection molding, and co-extrusion processes to continuously produce photovoltaic modules. This can improve corrosion resistance and aging resistance, and the product performance is also greatly improved after secondary processing. The composite material prepared by the method provided by this invention has significantly increased flexural strength, UV resistance, and salt spray corrosion resistance. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the preparation process of the resin-based composite material of the present invention; Figure 2 The composite material obtained in Example 2 of this invention; Figure 3 This is the composite material obtained in Example 5 of the present invention. Detailed Implementation

[0020] The following specific embodiments further illustrate the technical solution of the present invention. These specific embodiments do not represent a limitation on the scope of protection of the present invention. Non-essential modifications and adjustments made by others based on the concept of the present invention still fall within the scope of protection of the present invention.

[0021] The material property testing method in this invention is as follows: Bending strength test: The bending performance of the molded product was tested using the three-point bending method in accordance with the requirements of GB / T 1449 standard for testing the bending performance of fiber reinforced plastics.

[0022] UV resistant (120 kWh / m 2 Test: Tested in accordance with IEC 61215.

[0023] Salt spray corrosion resistance test: Tested in accordance with IEC 61701.

[0024] Example 1 Weigh out 10 parts of dicyclopentadiene, 2 parts of vinyltriethoxysilane, and 2 parts of Grubbs curing agent by weight. Add the weighed cyclopentadiene, silane, and curing agent to a high-speed disperser and stir at 1200 rpm for 20 minutes until the materials are evenly mixed to obtain a blend. Add the blend to the material tank of the dispensing machine.

[0025] 85 parts by weight of continuous E-glass fiber are drawn from the yarn rack and bundled and arranged parallel and uniformly through the yarn guide plate to control fiber tension. The bundled fiber yarn is then guided into the impregnation tank. The resin injection machine is turned on, and the resin blend is continuously injected into the impregnation tank at a rate of 100 g / min. The glass fiber yarn is fully impregnated with resin in the impregnation tank. The resin-impregnated fiber bundle then enters the preforming mold, where excess resin is squeezed out and the fiber is initially shaped. The temperature of the first zone in the molding mold is then adjusted to 40°C, the second zone to 80°C, and the third zone to 100°C. The speed of the pultrusion traction machine is adjusted to 0.5 m / min for continuous pultrusion molding. A composite material with a smooth and flat surface is obtained through the pultrusion molding process.

[0026] The composite material was subjected to material property tests, and the test results are shown in Table 1.

[0027] Example 2 Weigh out 18 parts by weight of a mixture of dicyclopentadiene and norbornene in a 1:1 mass ratio, 1 part of vinyltriethoxysilane, and 30 parts of Grubbs curing agent. Add the weighed materials to a high-speed disperser and disperse and stir at 1200 rpm for 20 minutes until the materials are evenly mixed to obtain a blend. Add the blend to the hopper of the dispensing machine.

[0028] Eighty parts by weight of continuous E-glass fiber are drawn from the yarn rack and bundled and arranged parallel and uniformly through the yarn guide plate to control fiber tension. The bundled fiber yarn is then guided into the impregnation tank. The resin injection machine is turned on, and the resin blend is continuously injected into the impregnation tank at a rate of 100 g / min. The glass fiber yarn is fully impregnated with resin in the impregnation tank. The resin-impregnated fiber bundle enters the preforming mold, where excess resin is squeezed out and the fiber is initially shaped. Subsequently, the temperature of zone one in the molding mold is adjusted to 100℃, zone two to 160℃, and zone three to 200℃. The pultrusion process speed is adjusted to 1.5 m / min. Ultra-high molecular weight polyethylene is attached through the pultrusion-compression molding process to obtain a composite material with a smooth and flat surface. The pressure of the compression molding process is 2 MPa.

[0029] The composite material was subjected to material property tests, and the test results are shown in Table 1.

[0030] Example 3 Weigh out 15 parts of dicyclopentadiene, 4 parts of epoxy resin, 0.01 parts of epoxy silane coupling agent, and 10 parts of Grubbs curing agent by weight. Add the weighed materials to a high-speed disperser and disperse and stir at 1200 rpm for 20 minutes until the materials are evenly mixed to obtain a blend. Add the blend to the material tank of the dispensing machine.

[0031] Eighty parts by weight of continuous E-glass fiber are drawn from the yarn rack and bundled and arranged parallel and uniformly through the yarn guide plate to control fiber tension. The bundled fiber yarn is then guided into the impregnation tank. The resin injection machine is turned on, and the resin blend is continuously injected into the impregnation tank at a rate of 100 g / min. The glass fiber yarn is fully impregnated with resin in the impregnation tank. The resin-impregnated fiber bundle enters the preforming mold, where excess resin is squeezed out and the material is initially shaped. Subsequently, the temperature of zone one in the molding mold is adjusted to 80℃, zone two to 160℃, and zone three to 180℃. The pultrusion process speed is adjusted to 1 m / min. A smooth and flat composite material is obtained by combining pultrusion-injection molding with nylon material PA66, where the injection pressure is 3 MPa.

[0032] The composite material was subjected to material property tests, and the test results are shown in Table 1.

[0033] Example 4 Weigh out 50 parts of dicyclopentadiene, 10 parts of epoxy resin, 2 parts of epoxy silane coupling agent, 5 parts of silicone oil, and 3 parts of Grubbs curing agent by weight. Add the weighed materials to a high-speed disperser and disperse and stir at 1200 rpm for 20 minutes until the materials are evenly mixed to obtain a blend. Add the blend to the material tank of the dispensing machine.

[0034] Fifty parts by weight of continuous E-glass fiber are drawn from the yarn rack and bundled and arranged parallel and uniformly through the yarn guide plate to control fiber tension. The bundled fiber yarn is then guided into the impregnation tank. The resin injection machine is turned on, and the resin blend is continuously injected into the impregnation tank at a rate of 100 g / min. The glass fiber yarn is fully impregnated with resin in the impregnation tank. The resin-impregnated fiber bundle enters the preforming mold, where excess resin is squeezed out and the fiber is initially shaped. Subsequently, the temperature of zone one in the molding mold is adjusted to 150°C, zone two to 200°C, and zone three to 220°C. The pultrusion process speed is adjusted to 0.7 m / min. Ultra-high molecular weight polyethylene is attached through the pultrusion-compression molding process to obtain a composite material with a smooth and flat surface. The pressure of the compression molding process is 5 MPa.

[0035] The composite material was subjected to material property tests, and the test results are shown in Table 1.

[0036] Example 5 Weigh out 8 parts cyclopentadiene, 11 parts phenolic resin, 0.8 parts epoxy silane coupling agent, 0.2 parts silicone oil, and 2 parts Grubbs curing agent by weight. Add the weighed materials to a high-speed disperser and disperse and stir at 1200 rpm for 20 minutes until the materials are evenly mixed to obtain a blend. Add the blend to the material tank of the dispensing machine.

[0037] Eighty parts by weight of continuous E-glass fiber are drawn from the yarn rack and bundled and arranged parallel and uniformly through the yarn guide plate to control fiber tension. The bundled fiber yarn is then guided into the impregnation tank. The resin injection machine is turned on, and the resin blend is continuously injected into the impregnation tank at a rate of 100 g / min. The glass fiber yarn is fully impregnated with resin in the impregnation tank. The resin-impregnated fiber bundle enters the preforming mold, where excess resin is squeezed out and the fiber is initially shaped. Subsequently, the temperature of zone one in the molding mold is adjusted to 80°C, zone two to 160°C, and zone three to 180°C. The pultrusion process speed is adjusted to 0.7 m / min. Through the pultrusion-co-extrusion molding process, an ultra-high-performance film is attached to obtain a composite material with a smooth and flat surface.

[0038] The composite material was subjected to material property tests, and the test results are shown in Table 1.

[0039] Example 6 Compared with Example 1, with other conditions unchanged, the pultrusion speed was adjusted to 1.5 m / min, and the material properties of the obtained composite material were tested. The test results are shown in Table 1.

[0040] Example 7 Compared with Example 6, with other conditions unchanged, the injection molding process described in Example 3 was added, and the resulting composite material was subjected to material performance testing. The test results are shown in Table 1.

[0041] Example 8 Compared with Example 6, with other conditions unchanged, the co-extrusion molding process described in Example 5 was added, and the resulting composite material was subjected to material performance testing. The test results are shown in Table 1.

[0042] Table 1. Performance test results of cyclic olefin composite materials in Examples 1-8

Claims

1. A method for preparing a resin-based composite material, characterized in that, Includes the following steps: S1. Disperse a mixture of cyclic olefin material, curing agent and silane coupling agent to obtain a blend; S2. The blend obtained in step S1 is mixed with fibers and pultruded to obtain a pre-cured molded body; S3. The pre-cured molded body obtained in S2 is subjected to secondary processing to obtain the composite material.

2. The preparation method according to claim 1, characterized in that, The cyclic olefin material comprises 5-50 parts by weight, the curing agent comprises 2-30 parts, the coupling agent comprises 0.01-2 parts, and the fiber comprises 40-90 parts.

3. The preparation method according to claim 1, characterized in that, The blend also contains additives; Preferably, the additive is one or both of thermosetting resin and release agent; Preferably, the thermosetting resin is selected from one or more of polyester resin, vinyl resin, phenolic resin, epoxy resin and polyurethane.

4. The preparation method according to claim 1, characterized in that, The cyclic olefin material is selected from one or more of cyclopentene, dicyclopentadiene, cyclopentadiene or norbornene; Preferably, the cyclic olefin material is selected from one or both of dicyclopentadiene and norbornene; Preferably, the silane coupling agent is selected from one or more of aminosilane coupling agents, epoxysilane coupling agents, acryloyloxysilane coupling agents, alkylsilane coupling agents, and vinylsilane coupling agents.

5. The preparation method according to claim 1, characterized in that, The fiber is one or more of glass fiber, carbon fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, basalt fiber, and hemp fiber; Preferably, the fiber is glass fiber.

6. The preparation method according to claim 1, characterized in that, The dispersion in step S1 is carried out by dispersion stirring or ultrasonic dispersion. Preferably, the dispersion and stirring are carried out by a high-speed disperser at a speed of 800-1500 rpm; Preferably, the dispersion and stirring are carried out by a high-speed disperser at a speed of 1200 rpm.

7. The preparation method according to claim 1, characterized in that, The pultrusion process speed in step S2 is 0.1~2m / min; Preferably, the pultrusion molding process speed is 0.5~1.5m / min; Preferably, the temperature of the pultrusion process is 30~350℃; Preferably, the pultrusion process is divided into at least three temperature zones, which are set as follows: Zone 1: 40℃~150℃, Zone 2: 60℃~280℃, and Zone 3: 60℃~320℃.

8. The method according to claim 1, characterized in that, The secondary processing in step S3 includes one or more of compression molding, injection molding, co-extrusion or pultrusion. Preferably, the pressure of the molding process is 2~5MPa; Preferably, the pressure of the injection molding process is 2~5MPa; Preferably, the secondary processing further includes the step of attaching a functional material to the surface of the pre-cured molded body, wherein the functional material is a corrosion-resistant material or an aging-resistant material.

9. A resin-based composite material, characterized in that, The resin-based composite material is prepared by the method according to any one of claims 1-8.

10. A photovoltaic module, characterized in that, It includes the resin-based composite material as described in claim 9.

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