Acrylic PV Backsheet Adhesion to PET Without Adhesives
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Solution Overview
Problem
Current photovoltaic module backsheet materials, such as polyvinyl fluoride (PVF), are expensive and have poor adhesion to polyethylene terephthalate (PET), requiring additional treatments and manufacturing steps, while existing alternatives lack cost-effectiveness and durability.
Innovation Solution
A multi-layer backsheet construction featuring an acrylic layer with at least 40% acrylic polymers, optionally containing impact modifiers and fluoropolymers, adhered directly to a PET support layer, providing excellent weather and moisture protection with high reflectivity and improved adhesion without the need for expensive fluoropolymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyvinyl fluoride (PVF) films are used as backsheet material, then weatherability and chemical resistance are improved, but cost increases and adhesion to PET deteriorates
Solution Approach 1:
The patent combines PVF film with PET substrate into a single laminated backsheet structure, integrating the weatherability benefits of PVF with the adhesion and mechanical properties of PET, eliminating the need for separate adhesive layers and simplifying manufacturing
Solution Approach 2:
The invention uses a composite material structure consisting of PVF and PET layers bonded together, where each material contributes its superior properties: PVF provides excellent weatherability and chemical resistance, while PET provides good adhesion and mechanical strength
2Reliability
If PVF/PET/PVF multi-layered laminated films are used, then weather protection is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the redundant middle PET layer from the traditional PVF/PET/PVF sandwich structure, simplifying the manufacturing process while maintaining the essential weather protection function through a single PVF/PET lamination
Solution Approach 2:
The invention segments the backsheet into functional layers with PVF providing external weather protection and PET providing internal adhesion and structural support, optimizing each layer's thickness and properties for its specific function
3Strength
If adhesive layers are added to improve PVF adhesion to PET, then adhesion is improved, but manufacturing steps and cost increase
Solution Approach 1:
The patent enables the PVF and PET materials to bond directly to each other through their inherent surface properties and lamination process, eliminating the need for separate adhesive materials and reducing manufacturing complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The acrylic-based backsheet offers enhanced weatherability, dimensional stability, and reflectivity at a lower cost than traditional materials, with improved adhesion to PET, reducing manufacturing complexity and costs.
Implementation Method 1
The acrylic layer adheres to a polymer support layer such as polyethylene terephthalate (PET)
Implementation Method 2
The backsheet provides excellent weatherability, environmental stability and reflectivity
Implementation Method 3
UV protection, and oxygen barrier properties necessary to protect the photocells from degradation induced by reaction with water, oxygen and/or UV radiation
Implementation Method 4
low water vapor transmission
Implementation Method 5
It may also contain fluoropolymers such as polyvinylidene fluoride to improve weathering, processibility and film formation
Data Source
AI summary
The invention relates to an acrylic layer (in the form of a coating, film or sheet) useful as part of a photovoltaic module backsheet. The acrylic layer contains at least 40 percent of one or more acrylic polymers, including an acrylic polymer matrix and optionally acrylic impact modifiers. The acrylic polymer is preferably a polymer, copolymer, or terpolymer containing at least 50 weight percent of methylmethacrylate monomer units. The acrylic layer is flexible and optionally contains high levels of white pigment. It may also contain fluoropolymers such as polyvinylidene fluoride to improve weathering, processibility and film formation. The acrylic layer adheres to a polymer support layer such as polyethylene terephthalate (PET). A preferred substrate is PET that is pre-treated to improve adhesion, but unprimed PET can also be used. The backsheet provides excellent weatherability, environmental stability and reflectivity as part of a photovoltaic module.