High-weather-resistance composite aluminum foil water-proof adhesive tape and preparation method thereof

Abstract

This invention relates to the field of adhesive tape technology, and in particular to a high weather-resistant composite aluminum foil water-blocking tape, comprising a composite substrate layer, a water-blocking adhesive layer, and a release paper layer. The composite substrate layer is connected to the release paper layer through the water-blocking adhesive layer. The composite substrate layer includes a three-layer co-extruded weather-resistant low-water-permeability film. The three-layer co-extruded weather-resistant low-water-permeability film is connected to an aluminum-plated prism layer through aluminum foil. The lower side of the aluminum-plated prism layer is connected to the water-blocking adhesive layer. The water-blocking adhesive layer is made of butyl pressure-sensitive adhesive and has a thickness of 20-150 μm. The butyl pressure-sensitive adhesive comprises the following components by weight: 50-100 parts butyl rubber, 20-60 parts polyisobutylene, 10-50 parts filler, 20-60 parts tackifying resin, 5-20 parts plasticizer, 0.5-5 parts antioxidant, and 0.5-3 parts vulcanizing agent. The three-layer co-extruded PEP layer of the composite aluminum foil substrate of this invention has excellent weather resistance and low water permeability. It can prevent scratches and protect the aluminum foil from decomposition under high temperature and high humidity conditions outdoors, thereby reducing production costs and improving the edge sealing efficiency of components.

Description

Technical Field

[0001] This invention relates to the field of adhesive tape technology, and in particular to a high weather-resistant composite aluminum foil water-blocking tape and its preparation method. Background Technology

[0002] Solar photovoltaic (PV) modules, as one of the clean energy sources, occupy an important position in China's power system. With the continuous development of double-glass high-efficiency PV modules, the energy conversion efficiency of the cells is increasing, but the power degradation caused by water vapor and oxygen corrosion is also becoming increasingly sensitive, placing higher demands on water vapor resistance. Aluminum foil has a large market share in the sealing field due to its near-zero water permeability and excellent airtightness. However, aluminum foil exposed to high humidity and high heat environments, especially in acidic environments, will decompose, requiring surface protection to extend the service life of the adhesive tape. Currently, the water vapor resistance of silicone sealant inside the aluminum frame is limited; water vapor can seep in through the module frame edges, causing delamination of the hot melt adhesive layer and corrosion of the silver grid lines, affecting the module's appearance and power output. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a high weather-resistant composite aluminum foil water-blocking tape and its preparation method to solve the above-mentioned problem.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a high weather-resistant composite aluminum foil water-blocking tape, comprising a composite substrate layer, a water-blocking adhesive layer, and a release paper layer. The composite substrate layer is connected to the release paper layer through the water-blocking adhesive layer. The composite substrate layer comprises a three-layer co-extruded weather-resistant low-water-permeability film. The three-layer co-extruded weather-resistant low-water-permeability film is connected to an aluminum-plated prism layer through an aluminum foil. The lower side of the aluminum-plated prism layer is connected to the water-blocking adhesive layer. The water-blocking adhesive layer is made of butyl pressure-sensitive adhesive and has a thickness of 20-150 μm. The butyl pressure-sensitive adhesive comprises the following components by weight: 50-100 parts butyl rubber, 20-60 parts polyisobutylene, 10-50 parts filler, 20-60 parts tackifying resin, 5-20 parts plasticizer, 0.5-5 parts antioxidant, and 0.5-3 parts vulcanizing agent.

[0005] As a further embodiment of the present invention, the three-layer co-extruded weather-resistant low-water-permeability membrane includes a transparent EVA layer, with transparent POE layers connected to both sides of the transparent EVA layer; the POE melt index of the transparent POE layer is 5-20 g / 10 min, the EVA melt index of the transparent EVA layer is between 1-10 g / 10 min, and the thickness of the three-layer co-extruded weather-resistant low-water-permeability membrane is 50-150 μm. The three-layer co-extruded weather-resistant low-water-permeability membrane is produced by screw extrusion and thermal bonding of POE / EVA / POE onto the surface of aluminum foil. POE material has excellent water resistance, adhesion, and aging resistance, while low-melt-index EVA has good airtightness and water resistance. The three-layer co-extrusion achieves low oxygen and water permeability, and PEP material does not decompose or become brittle under high temperature and humidity conditions, thus overcoming the problem of conventional PET and other materials decomposing and becoming brittle due to long-term outdoor aging when used as protective aluminum foil. Therefore, the middle layer aluminum foil can remain stable outdoors for a long time under the protection of PEP and butyl rubber without affecting the water resistance performance.

[0006] As a further aspect of the invention, the aluminum foil has a purity greater than 99% and a thickness of 20-100 μm. Aluminum foil has near-zero water vapor permeability and is widely used in packaging and applications requiring high airtightness. If the aluminum foil is too thick, it is difficult to properly seal the edges of components; if it is too thin, it is prone to breakage.

[0007] As a further embodiment of the present invention, the aluminum-plated prism layer is an aluminum foil-surface photocured prism layer, which is composed of several triangular prism structures arranged in parallel, with the direction of the prism structure parallel to the direction of the component sealing edge.

[0008] As a further aspect of the present invention, the base width of the triangular prism is 50-200 μm, and the apex angle of the prisms in the prism layer is any one or more of 90°, 120°, or 150°; the aluminum plating thickness of the aluminum-plated prism layer is 50-200 nm. The striped structure of the aluminum-plated prism not only increases the contact area of ​​the adhesive but also prevents adhesive residue at high temperatures. This aluminum-plated structure utilizes the low water permeability of the aluminum plating layer. Because its prism structure direction is parallel to the component sealing direction, multiple layers block water vapor from entering through the cross-section of the low water permeability butyl rubber pressure-sensitive adhesive layer, thereby greatly reducing the possibility of water vapor entering.

[0009] As a further aspect of the present invention, the butyl rubber has a molecular weight of 300,000 to 1,000,000, and the polyisobutylene has a molecular weight of 50,000 to 300,000. High molecular weight butyl rubber exhibits good cohesive strength and low water permeability, while low molecular weight polyisobutylene can balance the adhesive's tackiness and toughness.

[0010] As a further aspect of the present invention, the filler is a sheet-like inorganic filler, including one or more of carbon black, kaolin, alumina, mica powder, hydrotalcite, calcium carbonate, graphene, and boron nitride, with a particle size of 500-50 μm. This can both reinforce the strength of the adhesive layer and hinder the penetration and migration of water vapor within the adhesive layer, further reducing water vapor permeability.

[0011] As a further aspect of the present invention, the tackifying resin is one or more of rosin resin, petroleum resin, and terpene resin, and the plasticizer is one or more of paraffin oil, epoxidized soybean oil, phenolic resin, and fatty acid glycerides. The initial tack and peel strength of the components ensure a tight adhesion of the tape, maintaining tack even under high temperature and humidity, effectively protecting the components; the plasticizer possesses good softness and extensibility. It can reduce the hardness of butyl rubber and improve its processability and heat resistance.

[0012] As a further aspect of the present invention, the antioxidant is one or more of phenolic antioxidants or aldehyde-amine antioxidants, and the vulcanizing agent is one or more of sulfur, organic peroxides, or urethane. The antioxidant can capture aging free radicals, thus delaying or inhibiting the polymer oxidation process; the vulcanizing agent can further enlarge the polymer molecular chains through crosslinking points, thereby improving the cohesive force of the polymer layer.

[0013] A method for preparing a high weather-resistant composite aluminum foil water-blocking tape, the specific steps of which are as follows:

[0014] Step 1: A three-layer co-extrusion of POE / EVA / POE layer is performed by a screw extruder. After being thermally bonded to aluminum foil, a photocurable prism structure is made on the other side of the aluminum foil. Then, an aluminum layer is deposited on the prism surface to obtain a composite aluminum foil substrate layer.

[0015] Step 2: After the butyl rubber and polyisobutylene blocks are thoroughly mixed in an internal mixing unit, inorganic fillers, tackifying resins, plasticizers, antioxidants and vulcanizing agents are added in sequence and the mixture is further mixed until homogeneous.

[0016] Step 3: The adhesive obtained in Step 2 is extruded and coated onto the substrate prism surface in Step 1 by the screw, and then the release paper is attached and the mixture is wound up.

[0017] Because the present invention adopts the above technical solution, the advantages and positive effects of the present invention are as follows:

[0018] 1. The three-layer co-extruded PEP layer of the composite aluminum foil substrate of the present invention has excellent weather resistance and low water permeability, which can prevent scratches and protect the aluminum foil from decomposition under high temperature and high humidity outdoors, thereby reducing production costs and improving the edge sealing efficiency of components.

[0019] 2. The composite aluminum foil water-blocking tape described in this article uses aluminum foil as the main substrate, which has excellent water vapor barrier properties. The tape is relatively thin and has good conformability.

[0020] 3. The striped structure of the aluminized prism not only increases the contact area of ​​the adhesive and prevents residue at high temperatures, but also, because the prism structure is parallel to the edge sealing direction of the component, the low water permeability of the aluminized layer can block moisture from entering through the cross-section of the polyolefin-modified acrylate pressure-sensitive adhesive layer, thus greatly reducing the possibility of moisture ingress.

[0021] 4. By formulating a butyl rubber pressure-sensitive adhesive with high weather resistance and low water permeability, and adding fillers and other functional additives, it has good adhesion and weather resistance, and can stably block water vapor from corroding the double-glass module for a long time, thereby reducing the power decay of the module. Attached Figure Description

[0022] Figure 1 This is a cross-sectional view of a high weather-resistant composite aluminum foil water-blocking tape according to the present invention.

[0023] In the diagram: 1 is the transparent POE layer, 2 is the transparent EVA layer, 3 is the aluminum foil, 4 is the aluminized prism layer, 5 is the water-blocking adhesive layer, and 6 is the release paper layer. Detailed Implementation

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0025] like Figure 1 As shown, the present invention discloses a high weather-resistant composite aluminum foil water-blocking tape, comprising a composite substrate layer, a water-blocking adhesive layer 5, and a release paper layer 6. The composite substrate layer is connected to the release paper layer 6 via the water-blocking adhesive layer 5. The composite substrate layer comprises a three-layer co-extruded weather-resistant low-water-permeability film. The three-layer co-extruded weather-resistant low-water-permeability film is connected to an aluminum-plated prism layer 4 via an aluminum foil 3. The lower side of the aluminum-plated prism layer 4 is connected to the water-blocking adhesive layer 5. The composite substrate layer comprises a three-layer co-extruded weather-resistant low-water-permeability film. The three-layer co-extruded weather-resistant low-water-permeability film is connected to the aluminum-plated prism layer 4 via an aluminum foil 3. The three-layer co-extruded weather-resistant low-water-permeability film comprises a transparent EVA layer 2, and transparent POE layers 1 are respectively connected to both sides of the transparent EVA layer 2.

[0026] Example 1

[0027] Reference Figure 1 As shown, the composite aluminum foil water-blocking tape of this embodiment includes, from top to bottom, the following components...

[0028] ① The total thickness of the composite aluminum foil substrate layer is 90µm, including a 60µm thick three-layer co-extruded PEP layer and a 10µm aluminum foil; the prism layer has a 120° top adhesive, a height of 30µm, a width of 70µm, and an aluminum plating thickness of 100nm;

[0029] ② The thickness of the water-blocking butyl pressure-sensitive adhesive layer is 90um. Due to the groove structure of the prism, the adhesive layer penetrates into the prism after being combined with the composite aluminum foil substrate, and the total thickness of the tape is 180um.

[0030] The water-blocking adhesive layer is composed of the following: 70 parts butyl rubber (Alangxinke, CIIR RB100), 40 parts polyisobutylene (Jinan Xiangfa, 1300), 20 parts inorganic filler (Changzhou Sixth Element, SE1233 graphene), 30 parts tackifying resin (French DRT, Dercolyte S115, terpene phenol resin), 10 parts plasticizer (Nanjing Rongji, DOP), 2 parts antioxidant (Nantong Xinchang, KY405), and 1.5 parts vulcanizing agent (Dongguan Maiteng, MC-101).

[0031] Example 2

[0032] The water-blocking adhesive layer is composed of the following: 70 parts butyl rubber (Alangxinke, CIIR RB100), 40 parts polyisobutylene (Jinan Xiangfa, 1300), 20 parts inorganic filler (Changzhou Sixth Element, SE1233 graphene), 30 parts tackifying resin (French DRT, Dercolyte S115, terpene phenolic resin), 20 parts plasticizer (Nanjing Rongji, DOP), 2 parts antioxidant (Nantong Xinchang, KY405), and 1.5 parts vulcanizing agent (Dongguan Maiteng, MC-101).

[0033] Example 3

[0034] The water-blocking adhesive layer is composed of the following: 70 parts butyl rubber (Alangxinke, CIIR RB100), 40 parts polyisobutylene (Jinan Xiangfa, 1300), 50 parts inorganic filler (Changzhou Sixth Element, SE1233 graphene), 20 parts tackifying resin (French DRT, Dercolyte S115, terpene phenolic resin), 10 parts plasticizer (Nanjing Rongji, DOP), 2 parts antioxidant (Nantong Xinchang, KY405), and 1.5 parts vulcanizing agent (Dongguan Maiteng, MC-101).

[0035] Example 4

[0036] The water-blocking adhesive layer is composed of the following: 70 parts butyl rubber (Alangxinke, CIIR RB100), 40 parts polyisobutylene (Jinan Xiangfa, 1300), 20 parts inorganic filler (Changzhou Sixth Element, SE1233 graphene), 40 parts tackifying resin (French DRT, Dercolyte S115, terpene phenolic resin), 10 parts plasticizer (Nanjing Rongji, DOP), 2 parts antioxidant (Nantong Xinchang, KY405), and 1.5 parts vulcanizing agent (Dongguan Maiteng, MC-101).

[0037] Example 5

[0038] The water-blocking adhesive layer is composed of the following: 70 parts butyl rubber (Alan Newco, CIIR RB100), 40 parts polyisobutylene (Jinan Xiangfa, 1300), 20 parts inorganic filler (Changzhou Sixth Element, SE1233 graphene), 50 parts tackifying resin (French DRT, Dercolyte S115, terpene phenolic resin), 10 parts plasticizer (Nanjing Rongji, DOP), 2 parts antioxidant (Nantong Xinchang, KY405), and 1.5 parts vulcanizing agent (Dongguan Maiteng, MC-101).

[0039] Evaluation method:

[0040] The relevant properties of the composite aluminum foil water-blocking tape were tested and evaluated using the following methods:

[0041] (1) 180° peel strength: GB / T2792-2014 Test method for peel strength of adhesive tapes

[0042] (2) Peel strength after boiling in water at 85℃ for 24 hours:

[0043] Tape was applied to a SUS mirror steel plate and placed in an 85℃ water bath for 24 hours. After removal, the plate was left to stand at room temperature for 1 hour to test its peel strength.

[0044] (3) PCT aging 180° peel strength:

[0045] Tape was applied to a SUS mirror steel plate. The PCT aging chamber test conditions were 121℃, 100% relative humidity, 24H. After removing the plate and letting it stand at room temperature for 1H, the peel strength was tested.

[0046] (4) Peel strength of DH500 after 180° aging:

[0047] Tape was applied to a SUS mirror steel plate. The DH aging chamber test conditions were 85℃, 85% relative humidity, 500H. After removing the plate, it was left to stand at room temperature for 1H to test the peel strength.

[0048] (5) Peel strength of HF10 after 180° aging:

[0049] Tape was applied to a SUS mirror steel plate. The HF aging chamber was tested under the following conditions: 85% relative humidity and temperature range of -40 to 85℃ for 10 cycles. The plate was then removed and left to stand at room temperature for 1 hour before the peel strength was tested.

[0050] (6) Water vapor transmission rate: GB / T 15331-2020 Test method for water vapor transmission rate of pressure-sensitive adhesive tapes

[0051]

[0052] As can be seen from Table 1, compared with Example 2, increasing the proportion of tackifying resin in Example 5 can improve the adhesiveness of the tape and help prevent the tape from delaminating during aging; compared with Example 1, Example 2 has too much plasticizer which destroys the cohesion and the tape peel strength is low; compared with Example 1, Example 3 has too much powder added, the water resistance is not significantly improved, and the tape adhesiveness is significantly reduced; Example 5 has a relatively balanced initial peel strength and adhesiveness after aging, and a low water vapor permeability, with balanced performance.

[0053] While specific embodiments of the present invention have been described above, those skilled in the art should understand that these are merely illustrative examples, and various changes or modifications can be made to these embodiments without departing from the principles and essence of the present invention. The scope of protection of the present invention is defined only by the appended claims.

Claims

1. A high weather-resistant composite aluminum foil water-blocking tape, characterized in that: The material includes a composite substrate layer, a water-blocking adhesive layer (5), and a release paper layer (6). The composite substrate layer is connected to the release paper layer (6) through the water-blocking adhesive layer (5). The composite substrate layer includes a three-layer co-extruded weather-resistant low-water-permeability film. The three-layer co-extruded weather-resistant low-water-permeability film is connected to an aluminum-plated prism layer (4) through an aluminum foil (3). The lower side of the aluminum-plated prism layer (4) is connected to the water-blocking adhesive layer (5). The water-blocking adhesive layer (5) is made of butyl pressure-sensitive adhesive and has a thickness of 20-150 μm. The butyl pressure-sensitive adhesive includes the following components by weight: 50-100 parts butyl rubber, 20-60 parts polyisobutylene, 10-50 parts filler, 20-60 parts tackifying resin, 5-20 parts plasticizer, 0.5-5 parts antioxidant, and 0.5-3 parts vulcanizing agent.

2. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The three-layer co-extruded weather-resistant low-permeability membrane includes a transparent EVA layer (2), and transparent POE layers (1) are connected to both sides of the transparent EVA layer (2); the POE melt index of the transparent POE layer (1) is 5-20g / 10min, the EVA melt index of the transparent EVA layer (2) is between 1-10g / 10min, and the thickness of the three-layer co-extruded weather-resistant low-permeability membrane is 50-150um.

3. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The aluminum foil (3) has a purity greater than 99% and a thickness of 20-100 μm.

4. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The aluminum-plated prism layer (4) is an aluminum foil-surface photocured prism layer. The prism layer is composed of several triangular prism structures arranged in parallel, and the direction of the prism structure is parallel to the direction of the component sealing edge.

5. The high weather-resistant composite aluminum foil water-blocking tape according to claim 4, characterized in that: The base width of the triangular prism is 50-200μm, and the apex angle of the prism in the prism layer is any one or more of 90°, 120° or 150°; the aluminum plating thickness of the aluminum-plated prism layer (4) is 50-200nm.

6. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The butyl rubber has a molecular weight of 300,000 to 1,000,000, and the polyisobutylene has a molecular weight of 500,000 to 300,000.

7. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The filler is a sheet-like inorganic filler, including one or more of carbon black, kaolin, alumina, mica powder, hydrotalcite, calcium carbonate, graphene and boron nitride, with a particle size of 500-50 μm.

8. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The tackifying resin is one or more of rosin resin, petroleum resin and terpene resin, and the plasticizer is one or more of paraffin oil, epoxidized soybean oil, phenolic resin and fatty acid glycerides.

9. The high weather-resistant composite aluminum foil water-blocking tape according to claim 1, characterized in that: The antioxidant is one or more of phenolic antioxidants or aldehyde-amine antioxidants, and the vulcanizing agent is one or more of sulfur, organic peroxides, or ethyl carbamate.

10. A method for preparing a high weather-resistant composite aluminum foil water-blocking tape according to any one of claims 1-9, characterized in that: Detailed steps as follows: Step 1: A three-layer co-extrusion of POE / EVA / POE layer is performed by a screw extruder. After being thermally bonded to aluminum foil, a photocurable prism structure is made on the other side of the aluminum foil. Then, an aluminum layer is deposited on the prism surface to obtain a composite aluminum foil substrate layer. Step 2: After the butyl rubber and polyisobutylene blocks are thoroughly mixed in an internal mixing unit, inorganic fillers, tackifying resins, plasticizers, antioxidants and vulcanizing agents are added in sequence and the mixture is further mixed until homogeneous. Step 3: The adhesive obtained in Step 2 is extruded and coated onto the substrate prism surface in Step 1 by the screw, and then the release paper is attached and the mixture is wound up.

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