Aqueous Dispersion Backsheet for Photovoltaic Modules

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Solution Overview

Problem

Conventional methods for producing backsheets for photovoltaic modules using fluorine-based resins face issues with poor adhesive strength and environmental concerns due to the use of organic solvents, leading to increased costs and material degradation.

Innovation Solution

An aqueous dispersion composition comprising a crystalline fluorine-based polymer, pigment, and aqueous dispersion binder is used to form a resin layer on the backsheet, which enhances durability and weather resistance without the need for organic solvents, ensuring strong adhesion and preventing chalking phenomena.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fluorine-based resin is processed by film stacking or dissolved using organic solvent for coating, then weather resistance and durability are improved, but adhesive strength to base deteriorates and environmental harm increases

Engineering Contradiction:

Improveweather resistanceVSAvoidadhesive strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the solvent parameter from organic solvent to water, creating an aqueous dispersion system. This fundamental parameter change resolves the contradiction by eliminating the adhesive strength problem associated with organic solvents while maintaining weather resistance through the fluorine-based polymer structure. The aqueous dispersion allows proper adhesion to the base without the degradation issues of conventional methods.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite approach by combining fluorine-based polymer particles with aqueous dispersion medium and optional crosslinking agents. This composite material system achieves both weather resistance (from fluorine-based polymer) and adhesive strength (from aqueous dispersion and crosslinking), resolving the contradiction between these two properties.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If organic solvent is used to dissolve fluorine-based resin for coating, then resin layer formation is improved, but environmental harm and material cost increase

Engineering Contradiction:

Improveresin layer formationVSAvoidenvironmental harm

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the solvent parameter from organic solvent to water, creating an environmentally friendly aqueous dispersion system. This parameter change eliminates the environmental harm associated with organic solvents while maintaining resin layer formation capability through the dispersion mechanism and controlled drying process.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of solvent-based systems into a benefit by using water as the dispersion medium. The aqueous system provides all the necessary functions of organic solvents (dissolution, coating, drying) without the environmental harm, effectively turning a harmful approach into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If organic solvent is used for coating fluorine-based resin, then resin coating is achieved, but cost of materials increases

Engineering Contradiction:

Improveresin coatingVSAvoidcost of materials

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent changes the solvent from expensive organic solvents to water, significantly reducing material costs. The aqueous dispersion system achieves effective resin coating without the high cost of organic solvents, while the dispersion mechanism ensures proper coating quality.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a cost-effective, environmentally friendly backsheet with improved adhesive strength and weather resistance, maintaining durability and physical properties over time, while avoiding the use of toxic organic solvents.

Implementation Method 1

heating the composition to melt the fluorine-based polymer particles

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

an aqueous dispersion binder having a function of adhering to a base

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10505067B2Aqueous dispersion composition, back sheet for an eco-friendly photovoltaic module, and method for manufacturing same

Publication Date: 2019.12.10 LG CHEM LTD

AI summary

Provided are an aqueous dispersion composition, a backsheet for a photovoltaic module, a method of preparing the same, and a photovoltaic module. Since the aqueous dispersion composition includes a fluorine-based polymer, a pigment and an aqueous dispersion binder, a backsheet for a photovoltaic module using the aqueous dispersion composition is prepared without a toxic organic solvent, and thus is environmentally friendly and economical. In addition, as the aqueous dispersion binder is used, a chalking phenomenon in which the pigment projected on a surface of the backsheet is easily detached may be prevented, thereby enhancing both productivity and quality.