A kind of foam tape for photovoltaic module installation

Abstract

The utility model discloses a kind of foam tape for photovoltaic module installation, including substrate layer and the pressure-sensitive adhesive layer and release layer respectively sequentially arranged in the two sides of substrate layer, substrate layer is composed of polyurethane foam layer and the polytetrafluoroethylene foam layer being arranged in its two sides, the two surfaces of polytetrafluoroethylene foam layer are provided with silane coupling agent coating, polyurethane foam layer and polytetrafluoroethylene foam layer are connected by silane coupling agent coating and adhesive layer, pressure-sensitive adhesive layer and polytetrafluoroethylene foam layer are connected by silane coupling agent coating. The foam tape of the application has strong adhesive force, good cushioning effect, strong ultraviolet resistance and chemical corrosion resistance, and is suitable for special environments with high corrosion resistance and temperature resistance requirements, such as photovoltaic systems on roofs of chemical enterprises, installation of photovoltaic projects in high-altitude or extremely cold areas.

Description

Technical Field

[0001] This utility model relates to the field of adhesive tape technology, specifically to a foam adhesive tape for installing photovoltaic modules. Background Technology

[0002] With the development of building-integrated photovoltaic (BIPV) technology, the application of installing photovoltaic modules on building roofs is becoming increasingly widespread. The installation method of directly bonding photovoltaic modules to the roof panel surface using foam tape is simple and efficient, without damaging the original roof structure, and is increasingly being adopted by users.

[0003] Polyurethane (PU) foam tape is inexpensive and offers good cushioning and shock absorption, making it widely used in photovoltaic (PV) system installations in general industrial and commercial buildings. However, PU foam has limited resistance to UV radiation and chemical corrosion, and prolonged exposure to UV rays or strong acids and alkalis can easily lead to aging and performance degradation. Polytetrafluoroethylene (PTFE) foam tape possesses excellent UV resistance and chemical corrosion resistance, as well as superior high-temperature resistance, waterproofing, and sealing properties, making it suitable for special environments with high requirements for corrosion resistance and temperature resistance, such as PV systems on the roofs of chemical plants and PV projects in high-altitude or extremely cold regions. However, PTFE foam has high raw material costs, low surface energy, and is difficult to bond. Therefore, developing a low-cost foam tape with good cushioning and shock absorption, strong adhesion, and strong UV and chemical corrosion resistance is of great significance in this field. Utility Model Content

[0004] To address the aforementioned problems, this utility model provides a foam tape for installing photovoltaic modules.

[0005] The technical solution adopted in this utility model is:

[0006] A foam tape for installing photovoltaic modules includes a substrate layer and a pressure-sensitive adhesive layer and a release layer respectively disposed on both sides of the substrate layer. The substrate layer is composed of a polyurethane foam layer and polytetrafluoroethylene (PTFE) foam layers disposed on both sides thereon. Both surfaces of the PTFE foam layers are coated with a silane coupling agent. The polyurethane foam layers and the PTFE foam layers are connected by the silane coupling agent coating and an adhesive layer. The pressure-sensitive adhesive layer and the PTFE foam layers are connected by the silane coupling agent coating.

[0007] Furthermore, the thickness of the polytetrafluoroethylene foam layer is 0.1-0.2 mm, and the thickness of the polyurethane foam layer is 1-10 mm.

[0008] By adopting the above technical solution, the advantages of both materials can be fully utilized while reducing costs.

[0009] Furthermore, the thickness of the pressure-sensitive adhesive layer is 10-100μm.

[0010] If the pressure-sensitive adhesive layer is too thin, it will not have enough adhesion to firmly fix the battery module; if it is too thick, it will increase the cost.

[0011] Furthermore, the thickness of the release layer is 25-100 μm.

[0012] If the release layer is too thin, it is easily damaged and loses its protective function; if it is too thick, it will increase the overall thickness and cost of the tape.

[0013] Furthermore, the thickness of the adhesive layer is 10-30 μm.

[0014] If the adhesive layer is too thin, it cannot guarantee sufficient adhesion; if it is too thick, it will affect the overall performance of the tape.

[0015] Furthermore, the silane coupling agent coating is an aminosilane coupling agent coating or an epoxysilane coupling agent coating. More preferably, it is γ-aminopropyltriethoxysilane (KH-550) or γ-glycidoxypropyltrimethoxysilane (KH-560).

[0016] The amino groups in aminosilane coupling agents possess certain reactivity, allowing them to react with the active groups in the polyurethane foam layer. They can also bond to the surface of polytetrafluoroethylene (PTFE) foam through physical adsorption, thereby improving interlayer adhesion. The epoxy groups in epoxy-based coupling agents exhibit high reactivity, enabling them to react chemically with various materials to form stable chemical bonds. This strengthens the chemical bond between the PTFE foam layer, the polyurethane foam layer, and the pressure-sensitive adhesive layer, improving the durability and stability of the bond.

[0017] Furthermore, the adhesive layer is a polyurethane adhesive layer.

[0018] Polyurethane adhesives can achieve good compatibility and bonding effects, forming a strong bond between polyurethane foam layers and polytetrafluoroethylene foam layers, and also have good flexibility and weather resistance.

[0019] Furthermore, the pressure-sensitive adhesive layer is an organosilicon pressure-sensitive adhesive layer.

[0020] Silicone pressure-sensitive adhesives have excellent high and low temperature resistance, weather resistance and electrical insulation properties. They can maintain their bonding performance under extreme temperature conditions and also have good bonding effect on difficult-to-bond materials such as polytetrafluoroethylene.

[0021] The beneficial effects of this utility model are:

[0022] 1. Polytetrafluoroethylene (PTFE) possesses excellent chemical stability, resistance to high and low temperatures, UV resistance, and waterproof properties, effectively resisting the corrosive effects of harsh external environments on photovoltaic modules and extending their service life. Polyurethane foam has good cushioning, flexibility, and adhesion properties, absorbing and dispersing the impact forces on photovoltaic modules during installation and use, protecting them from damage. The combination of polyurethane foam layers and PTFE foam layers forms the substrate layer, fully leveraging the advantages of both materials. This allows the foam tape to provide excellent cushioning while also resisting the effects of various harsh environments, offering more comprehensive protection for photovoltaic modules. Furthermore, it can relatively reduce the amount of PTFE used, lowering raw material costs.

[0023] 2. Silane coupling agents can improve the low surface energy of PTFE foam, enhancing its adhesion to the polyurethane foam layer and pressure-sensitive adhesive layer. One end of the agent can chemically react or physically adsorb with PTFE, while the other end can interact with the polyurethane or pressure-sensitive adhesive, thus forming a stable bonding layer at the interface. The adhesive layer can further fill the tiny gaps between the PTFE foam layer and the polyurethane foam layer, enhancing the bonding strength between the two layers, making the entire substrate layer a whole, and improving the overall performance of the foam tape. Attached Figure Description

[0024] Figure 1 This is a structural diagram of the foam tape used for installing photovoltaic modules in this application. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below in conjunction with the accompanying drawings and preferred embodiments.

[0026] See Figure 1 A foam tape for mounting photovoltaic modules includes a substrate layer 10 and a first silane coupling agent coating 20, a pressure-sensitive adhesive layer 30, and a release layer 40, which are symmetrically disposed on both sides of the substrate layer. The substrate layer 10 is composed of a polyurethane foam layer 11 and an adhesive layer 12, a second silane coupling agent coating 13, and a polytetrafluoroethylene (PTFE) foam layer 14, which are symmetrically disposed on both sides of the polyurethane foam layer 11. The first silane coupling agent coating 20 and the second silane coupling agent coating 13 are formed by applying silane coupling agent to both sides of the PTFE foam layer 14.

[0027] The thickness of the polyurethane foam layer 11 is selected within the range of 1-10mm, and the thickness of the polytetrafluoroethylene foam layer is selected within the range of 0.1-0.2mm. Within this thickness range, the advantages of both materials can be fully utilized, while costs can be reduced as much as possible.

[0028] The preferred material for the silane coupling agent coating is an aminosilane coupling agent or an epoxysilane coupling agent, such as γ-aminopropyltriethoxysilane (KH-550) or γ-glycidoxypropyltrimethoxysilane (KH-560). This silane coupling agent coating is sprayed onto both sides of the polytetrafluoroethylene (PTFE) foam layer to improve the adhesion of the PTFE foam. The spraying process is an existing technology; however, by employing high-precision coating equipment and optimizing and monitoring the production process, the uniformity of the coating can be ensured.

[0029] The preferred material for adhesive layer 12 is polyurethane adhesive, which exhibits good bonding performance with both silane coupling agents and polyurethane foam. The thickness of the adhesive layer is selected within the range of 10-30 μm.

[0030] The preferred material for the pressure-sensitive adhesive layer 30 is an organosilicon pressure-sensitive adhesive; organosilicon pressure-sensitive adhesives have good bonding properties with silane coupling agents. The thickness of the pressure-sensitive adhesive layer is selected in the range of 10-100 μm.

[0031] Release layer 40 can be release paper or release film, with a thickness selected in the range of 25-100μm.

[0032] The preparation method of the above-mentioned photovoltaic module installation foam tape is as follows:

[0033] (1) Place the polytetrafluoroethylene foam in an organic solvent (such as acetone, ethanol, etc.) for ultrasonic cleaning to remove surface oil, dust and other impurities, then rinse it with deionized water, and finally dry it in a drying oven for later use.

[0034] (2) Dilute the silane coupling agent in an organic solvent (such as ethanol, isopropanol, etc.) at a certain ratio (usually 0.1%-1%); apply the diluted silane coupling agent solution evenly to both surfaces of the polytetrafluoroethylene foam layer by spraying; after coating, place it at room temperature for a period of time to allow the silane coupling agent to fully contact the polytetrafluoroethylene surface, and then dry it for 1-2 hours to allow the silane coupling agent to form a stable coating on the polytetrafluoroethylene surface.

[0035] (3) Apply polyurethane adhesive to one side of the treated polytetrafluoroethylene foam layer, and after drying and curing, form adhesive layer 12. Apply silicone pressure-sensitive adhesive to the other side, and after drying and curing, form pressure-sensitive adhesive layer 30.

[0036] (4) Stack the polyurethane foam layer 11, polytetrafluoroethylene foam layer 14 and release paper in sequence, and then hot press them at high temperature to obtain the final product.

[0037] The above processes are all existing technologies, and the technology is relatively mature.

[0038] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications are also within the protection scope of the present utility model.

Claims

1. A foam tape for installing photovoltaic modules, comprising a substrate layer and a pressure-sensitive adhesive layer and a release layer respectively disposed on both sides of the substrate layer, characterized in that, The substrate layer consists of a polyurethane foam layer and polytetrafluoroethylene foam layers on both sides thereof. Both surfaces of the polytetrafluoroethylene foam layer are coated with a silane coupling agent. The polyurethane foam layer and the polytetrafluoroethylene foam layer are connected by the silane coupling agent coating and the adhesive layer. The pressure-sensitive adhesive layer is connected to the polytetrafluoroethylene foam layer by the silane coupling agent coating.

2. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The thickness of the polytetrafluoroethylene foam layer is 0.1-0.2 mm, and the thickness of the polyurethane foam layer is 1-10 mm.

3. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The thickness of the pressure-sensitive adhesive layer is 10-100μm.

4. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The thickness of the release layer is 25-100μm.

5. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The thickness of the adhesive layer is 10-30 μm.

6. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The silane coupling agent coating is either an aminosilane coupling agent coating or an epoxysilane coupling agent coating.

7. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The adhesive layer is a polyurethane adhesive layer.

8. The foam tape for installing photovoltaic modules according to claim 1, characterized in that, The pressure-sensitive adhesive layer is an organosilicon pressure-sensitive adhesive layer.

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