Thermoplastic polyolefin carrier film and process for its production

Abstract

This invention relates to the field of photovoltaic module encapsulation materials technology, specifically a thermoplastic polyolefin carrier film, comprising 10-100 parts of thermoplastic polyolefin, 0.1-5 parts of a crosslinking agent, 0.1-5 parts of a tackifier, and 0.1-5 parts of a light stabilizer. The thermoplastic polyolefin, crosslinking agent, tackifier, and light stabilizer are stirred evenly, and the raw materials are melt-extruded through a screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier film. After casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding, the thermoplastic polyolefin carrier film is obtained. The thermoplastic polyolefin carrier film is irradiated to form a crosslinked network through electron beam radiation. This invention utilizes γ-methacryloyloxypropyltrimethoxysilane and vinyltrimethoxysilane to ensure the adhesion between the carrier film and the BC solar cell after high-temperature aging, improve the high-temperature resistance of the module, and effectively reduce the generation of EL shadows in the module under high-temperature conditions.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module encapsulation materials technology, and in particular to a thermoplastic polyolefin carrier film and its preparation process. Background Technology

[0002] The carrier film is a high-performance encapsulation material developed to adapt to and enable the disruptive battery technology of "full back electrode + no main grid". Its core value lies in solving the "fixation problem" and "insulation problem" in the OBB interconnect process. With excellent resistance to displacement, electrical insulation and environmental durability, it ensures the realization of the ultra-high efficiency and aesthetic value of BC cells, and ultimately improves the reliability and production yield of the module.

[0003] The TPO carrier film is laminated with the back-side welding wire of the BC module using a Niu lamination method. This lamination stage ensures good metallization contact between the cell and the welding wire, while also providing encapsulation reliability. However, this encapsulation reliability presents challenges to the high-temperature resistance of the TPO carrier film and ensuring good adhesion between the carrier film and the cell. In existing technologies, the adhesion between the carrier film and the cell tends to decrease or even delaminate after the module has been subjected to high temperatures. Combinations of different types of TPO particles, along with γ-methacryloyloxypropyltrimethoxysilane and vinyltrimethoxysilane, can address this problem. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a thermoplastic polyolefin carrier film and its preparation process to solve the above-mentioned problem.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a thermoplastic polyolefin carrier film, comprising the following components in parts by weight:

[0006] 10-100 parts of thermoplastic polyolefin

[0007] Crosslinking agent 0.1-5 parts

[0008] 0.1-5 parts of tackifier

[0009] 0.1-5 parts of light stabilizer.

[0010] As a further embodiment of the present invention, the thermoplastic polyolefin is any one or more of POE, POP, COC, PP, or PE.

[0011] As a further embodiment of the present invention, the crosslinking agent is one or more of triallyl isocyanate, trimethylolpropane triacrylate, ethoxylated trimethylolpropane triacrylate, 1,6-hexanediol diacrylate, tri(2-hydroxyethyl)isocyanurate triacrylate, or bis(trimethylolpropane)tetraacrylate.

[0012] As a further embodiment of the present invention, the tackifier is any one or more of 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, γ-(2,3-epoxypropoxy)propyltrimethoxysilane, γ-methacryloyloxypropyltrimethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, or N-β-aminoethyl-γ-aminopropyltrimethoxysilane.

[0013] As a further embodiment of the present invention, the light stabilizer is a hindered amine light stabilizer.

[0014] As a further embodiment of the present invention, the hindered amine light stabilizer is a dimethylpiperidine derivative or a disubstituted piperidine derivative.

[0015] As a further aspect of the present invention, the basis weight of the thermoplastic polyolefin carrier film is in the range of 50-100 g / m².

[0016] As a further embodiment of the present invention, the thermoplastic polyolefin carrier film is bonded to the back welding wire of the BC assembly.

[0017] A process for preparing a thermoplastic polyolefin carrier film, comprising the following specific steps:

[0018] S1, Raw material mixing: Stir the thermoplastic polyolefin, crosslinking agent, tackifier, and light stabilizer until homogeneous.

[0019] S2, melt extrusion, the raw material in S1 is melt-extruded through a screw extruder, the extrusion temperature and screw speed are controlled to obtain a single-layer or multi-layer TPO carrier membrane;

[0020] S3, casting molding, through casting, embossing, cooling and shaping, thickness measurement, traction, slitting and winding, to obtain thermoplastic polyolefin carrier film;

[0021] S4, Pretreatment, involves irradiating the thermoplastic polyolefin carrier film to form a cross-linked network through electron beam radiation.

[0022] Because this invention employs the above-described technical solution, its advantages and positive effects are as follows: By using γ-methacryloyloxypropyltrimethoxysilane and vinyltrimethoxysilane, the adhesion between the carrier film and the BC solar cell is ensured after high-temperature aging, improving the module's high-temperature resistance and effectively reducing the generation of EL shadows under high-temperature conditions. Combinations of different types of TPO particles, along with this additive system, can solve the problem of reduced adhesion between the carrier film and the solar cell, and even delamination, after high-temperature processing. Attached Figure Description

[0023] Figure 1 This is the initial EL image of the TPO carrier film and BC solar cell in Example 1.

[0024] Figure 2 This is the initial EL image of the TPO carrier film and BC solar cell in Example 2.

[0025] Figure 3 This is the initial EL image of the TPO carrier film and BC solar cell in Comparative Example 1.

[0026] Figure 4 This is the initial EL image of the TPO carrier film and BC solar cell in Comparative Example 2.

[0027] Figure 5 This is an EL image of the TPO carrier film and BC solar cell after 145°C for 4 hours in Example 1.

[0028] Figure 6 This is an EL image of the TPO carrier film and BC solar cell after 145°C for 4 hours in Example 2.

[0029] Figure 7 This is the EL image of the TPO carrier film and BC solar cell in Comparative Example 1 after 145℃ for 4 hours.

[0030] Figure 8 This is the EL image of the TPO carrier film and BC solar cell in Comparative Example 2 after 145℃ for 4 hours. Detailed Implementation

[0031] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0032] Example 1

[0033] By weight, the raw materials for the high-temperature resistant, high-adhesion TPO carrier membrane monolayer structure include:

[0034] 20 parts of POE (ENGAGE PV 8660), 40 parts of POP (ENGAGE 8450), 40 parts of PE (Evolue SP2520), 0.5 parts of hindered amine light stabilizer (UV-770), 0.5 parts of co-crosslinking agent (TAICROS), 0.2 parts of tackifier KBM-503 and 0.5 parts of tackifier KBM-1003.

[0035] The preparation steps are as follows:

[0036] S1, Raw material mixing, granules and additives are stirred evenly:

[0037] S2, melt extrusion, involves melting and extruding the raw material through a single-screw, twin-screw, or three-screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier membrane;

[0038] S3, casting molding, involves casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding to obtain a weight ≤100g / m². 2 TPO carrier membrane;

[0039] S4, pretreatment, involves irradiating the film to form a cross-linked network through electron beam radiation.

[0040] Example 2

[0041] By weight, the raw materials for the high-temperature resistant, high-adhesion TPO carrier membrane monolayer structure include:

[0042] 10 parts POE (ENGAGE PV 8660), 30 parts POP (ENGAGE 8450), 30 parts PP (Excellen FH3471M), 30 parts PE (Evolue SP0540), 0.5 parts hindered amine light stabilizer (UV-770), 0.5 parts co-crosslinking agent (TAICROS), 0.2 parts tackifier KBM-503 and 0.5 parts KBM-1003.

[0043] The preparation steps are as follows:

[0044] S1, Raw material mixing, granules and additives are stirred evenly:

[0045] S2, melt extrusion, involves melting and extruding the raw material through a single-screw, twin-screw, or three-screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier membrane;

[0046] S3, casting molding, involves casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding to obtain a weight ≤100g / m². 2 TPO carrier membrane;

[0047] S4, pretreatment, involves irradiating the film to form a cross-linked network through electron beam radiation.

[0048] Example 3

[0049] By weight, the raw materials for the high-temperature resistant, high-adhesion TPO carrier membrane monolayer structure include:

[0050] 30 parts of POE (ENGAGE PV 8688), 30 parts of PP (Excellen FH3471M), 40 parts of PE (Evolue SP0540), 0.5 parts of hindered amine light stabilizer (UV-770), 0.5 parts of co-crosslinking agent (TAICROS), 0.2 parts of tackifier KBM-503 and 0.5 parts of tackifier KBM-1003.

[0051] The preparation steps are as follows:

[0052] S1, Raw material mixing, granules and additives are stirred evenly:

[0053] S2, melt extrusion, involves melting and extruding the raw material through a single-screw, twin-screw, or three-screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier membrane;

[0054] S3, casting molding, involves casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding to obtain a weight ≤100g / m². 2 TPO carrier membrane;

[0055] S4, pretreatment, involves irradiating the film to form a cross-linked network through electron beam radiation.

[0056] Example 4

[0057] By weight, the raw materials for the high-temperature resistant, high-adhesion TPO carrier membrane bilayer structure include:

[0058] Layer A: 20 parts POE (ENGAGE PV 38688), 20 parts POP (ENGAGE 8450), 30 parts PP (Excellen FH3471M), 30 parts PE (Evolue SP0540), 0.5 parts hindered amine light stabilizer (UV-770), 0.5 parts co-crosslinking agent (TAICROS), and 0.2 parts tackifier KBM-503.

[0059] Layer B (for the battery): 20 parts POE (ENGAGE PV 8660), 50 parts COC (ZEONEX E48R), 30 parts PE (Evolue SP2520), 0.5 parts hindered amine light stabilizer (UV-770), 0.5 parts co-crosslinking agent (TAICROS), 0.2 parts tackifier KBM-503 and 0.5 parts KBM-1003.

[0060] The preparation steps are as follows:

[0061] S1, Raw material mixing, granules and additives are stirred evenly:

[0062] S2, melt extrusion, involves melting and extruding the raw material through a single-screw, twin-screw, or three-screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier membrane;

[0063] S3, casting molding, involves casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding to obtain a weight ≤100g / m². 2 TPO carrier membrane;

[0064] S4, pretreatment, involves irradiating the film to form a cross-linked network through electron beam radiation.

[0065] Example 5

[0066] By weight, the raw materials for the three-layer structure of the high-temperature resistant and high-adhesion TPO carrier membrane include:

[0067] Layer A (side layer): 20 parts POE (ENGAGE PV 8660), 50 parts POP (ENGAGE 8450), 30 parts PE (EvolueSP0540), 0.5 parts hindered amine light stabilizer (UV-770), 0.5 parts co-crosslinking agent (TAICROS), 0.2 parts tackifier KBM-503 and 0.5 parts KBM-1003.

[0068] Layer B (intermediate layer): 20 parts POE (ENGAGE PV 8660), 40 parts COC (ZEONEX E48R), 40 parts PE (ELITE5815), 0.5 parts hindered amine light stabilizer (UV-770), 0.5 parts co-crosslinking agent (TAICROS), and 0.2 parts tackifier (KBM-1003).

[0069] The preparation steps are as follows:

[0070] S1, Raw material mixing, granules and additives are stirred evenly:

[0071] S2, melt extrusion, involves melting and extruding the raw material through a single-screw, twin-screw, or three-screw extruder, controlling the extrusion temperature and screw speed to obtain a single-layer or multi-layer TPO carrier membrane;

[0072] S3, casting molding, involves casting, embossing, cooling and shaping, thickness measurement, traction, slitting, and winding to obtain a weight ≤100g / m². 2 TPO carrier membrane;

[0073] S4, pretreatment, involves irradiating the film to form a cross-linked network through electron beam radiation.

[0074] Comparative Example 1

[0075] The difference between Comparative Example 1 and Example 1 is that no tackifiers KBM-503 and KBM-1003 are added. In this case, 20 parts of POE (ENGAGE PV8660), 40 parts of POP (ENGAGE 8450), 40 parts of PE (Evolue SP2520), 0.5 parts of hindered amine light stabilizer (UV-770), and 0.5 parts of crosslinking agent (TAICROS) are added. The process steps are the same as in Example 1.

[0076] Comparative Example 2

[0077] The difference between Comparative Example 2 and Example 2 is that no tackifiers KBM-503 and KBM-1003 are added. The following ingredients are used: 10 parts POE (ENGAGE PV8660), 30 parts POP (ENGAGE 8450), 30 parts PP (Excellen FH3471M), 30 parts PE (Evolue SP0540), 0.5 parts hindered amine light stabilizer (UV-770), and 0.5 parts co-crosslinking agent (TAICROS). The process steps are the same as in Example 2.

[0078] Table 1 shows the adhesion test results of Examples 1-5 and Comparative Examples 1-2 after baking.

[0079]

[0080] From Table 1 and Figure 1-8 It can be seen that after high-temperature aging under different conditions, the adhesion force and EL diagram of the TPO carrier film and BC cell in the comparative examples and comparative examples show that γ-methacryloyloxypropyltrimethoxysilane and vinyltrimethoxysilane can indeed ensure the adhesion force between the carrier film and the cell at high temperatures and reduce the generation of EL shadows.

[0081] 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 thermoplastic polyolefin carrier film, characterized in that: Including the following Components by weight: 10-100 parts of thermoplastic polyolefin Crosslinking agent 0.1-5 parts 0.1-5 parts of tackifier 0.1-5 parts of light stabilizer.

2. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The thermoplastic polyolefin is any one or more of POE, POP, COC, PP, or PE.

3. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The co-crosslinking agent is one or more of triallyl isocyanate, trimethylolpropane triacrylate, ethoxylated trimethylolpropane triacrylate, 1,6-hexanediol diacrylate, tri(2-hydroxyethyl) isocyanurate triacrylate, or bis(trimethylolpropane)tetraacrylate.

4. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The tackifier is any one or more of 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, γ-(2,3-epoxypropoxy)propyltrimethoxysilane, γ-methacryloyloxypropyltrimethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane, vinyltri(2-methoxyethoxy)silane, or N-β-aminoethyl-γ-aminopropyltrimethoxysilane.

5. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The light stabilizer is a hindered amine light stabilizer.

6. The thermoplastic polyolefin carrier film according to claim 5, characterized in that: The hindered amine light stabilizer is a dimethylpiperidine derivative or a disubstituted piperidine derivative.

7. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The basis weight range of the thermoplastic polyolefin carrier film is 50-100 g / m².

8. The thermoplastic polyolefin carrier film according to claim 1, characterized in that: The thermoplastic polyolefin carrier film is bonded to the back of the BC assembly using a press-fit wire.

9. The preparation process of a thermoplastic polyolefin carrier film according to any one of claims 1-8, characterized in that: Detailed steps as follows: S1, Raw material mixing: Stir the thermoplastic polyolefin, crosslinking agent, tackifier, and light stabilizer until homogeneous. S2, melt extrusion, the raw material in S1 is melt-extruded through a screw extruder, the extrusion temperature and screw speed are controlled to obtain a single-layer or multi-layer TPO carrier membrane; S3, casting molding, through casting, embossing, cooling and shaping, thickness measurement, traction, slitting and winding, to obtain thermoplastic polyolefin carrier film; S4, Pretreatment, involves irradiating the thermoplastic polyolefin carrier film to form a cross-linked network through electron beam radiation.

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