Polycarbonate Resin Composition for Solar PV Structural Members
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Solution Overview
Problem
Existing polycarbonate resin compositions for solar photovoltaic power generation modules lack sufficient impact resistance, surface dielectric breakdown-resisting characteristics, and flame retardancy, especially in thin structures, and increasing the blending amount of silsesquioxane as a flame retardant compromises these properties.
Innovation Solution
A polycarbonate resin composition is developed by blending a specific PC-POS copolymer with organic acid metal salts, polytetrafluoroethylene, titanium dioxide, carbon black, and silsesquioxane in specific ratios, along with an antioxidant and polyorganosiloxane, to enhance impact resistance, surface dielectric breakdown-resisting characteristics, and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the structure member is thinned to meet design demands, then weight and material usage are reduced, but flame retardancy becomes insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by incorporating silsesquoxane (0.01-5 parts by mass) and organic acid metal salt (0.01-1 part by mass) to enhance flame retardancy at the molecular level, allowing thin structures to achieve adequate flame resistance without increasing thickness.
Solution Approach 2:
The silsesquoxane and organic acid metal salt act as intermediary flame retardant agents that provide flame protective functionality within the thin polymer matrix, enabling thin-walled structures to achieve flame retardancy without relying on increased material thickness.
2Strength
If PC-POS copolymer is used alone to achieve low-temperature impact characteristic, then impact resistance is improved, but tracking resistance becomes poor
Solution Approach 1:
The patent formulates a composite resin composition combining PC-POS copolymer (providing impact resistance) with silsesquoxane, organic acid metal salt, and other additives (providing tracking resistance and flame retardancy). This composite approach allows simultaneous achievement of low-temperature impact characteristic and adequate tracking resistance that cannot be achieved with PC-POS copolymer alone.
Solution Approach 2:
The patent introduces specific functional additives (silsesquoxane, organic acid metal salt) in controlled amounts to provide localized tracking resistance properties while maintaining the bulk impact resistance properties of the PC-POS copolymer matrix, achieving different performance requirements in different aspects of the material.
Data Source
AI summary
Provided are a polycarbonate resin composition, a molded article, and a structure member for solar photovoltaic power generation, the polycarbonate resin composition including: (A) 100 parts by mass of a resin mixture formed of 30 mass% to 100 mass% of a polycarbonate-polyorganosiloxane copolymer (A-1) having a repeating unit represented by the general formula (I) and a repeating unit represented by the general formula (II), and having an average chain length n of a polyorganosiloxane moiety of from 70 to 500, and 70 mass% to 0 mass% of an aromatic polycarbonate resin (A-2) except the polycarbonate-polyorganosiloxane copolymer (A-1); (B) 0.08 part by mass to 0.3 part by mass of a silsesquioxane; (C) 0.05 part by mass to 0.2 part by mass of an alkaline metal salt and/or an alkaline earth metal salt of an organic sulfonic acid; (D) 0 parts by mass to 0.3 part by mass of a polytetrafluoroethylene having a fibril-forming ability; (E) 1 part by mass to 10 parts by mass of titanium dioxide; and (F) 0.1 part by mass to 3 parts by mass of carbon black.