Photovoltaic Backsheet Intermediate Film with Split Resin Cross-Linking
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Solution Overview
Problem
The production process of photovoltaic modules is lengthy and complex due to the slow cross-linking process of resin layers in backsheets, which requires high temperatures and special cross-linking agents, leading to increased production times and costs.
Innovation Solution
The cross-linking process is divided into two sub-steps: partial cross-linking in the coating line ovens and completion during the lamination process, using blocked isocyanates that are activated by temperature, allowing for faster and more controlled cross-linking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cross-linking agents (aliphatic poly-isocyanates) are used with high temperature exposure, then complete cross-linking of the resin layer is achieved, but the production time increases up to six days
Solution Approach 1:
The patent changes the chemical parameters of the cross-linking agent from traditional aliphatic poly-isocyanates to blocked isocyanates with different reactivity characteristics. This parameter change allows the cross-linking reaction to proceed at lower temperatures and faster rates, reducing production time from six days to a few hours while maintaining complete cross-linking.
Solution Approach 2:
The blocked isocyanates are pre-prepared in a blocked state during resin application, allowing the resin layer to be applied and positioned before the cross-linking reaction is activated. This preliminary preparation enables faster overall processing by eliminating the need for immediate high-temperature exposure.
2Productivity
If high temperatures are used for cross-linking, then the cross-linking process completes faster, but the complexity of the production process increases due to special equipment requirements
Solution Approach 1:
By changing from traditional cross-linking agents requiring sustained high temperatures to blocked isocyanates that react at lower temperatures, the patent simplifies the thermal processing equipment requirements while maintaining fast cross-linking speeds. This reduces device complexity without sacrificing productivity.
3Reliability
If traditional cross-linking processes are used, then complete cross-linking is achieved, but the production cost increases due to long processing times and special equipment
Solution Approach 1:
The patent changes the cross-linking agent parameters to blocked isocyanates that enable complete cross-linking at lower temperatures and shorter times, directly reducing energy consumption and equipment requirements. This parameter change lowers manufacturing costs while maintaining the reliability of the resin layer properties.
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
This approach reduces production time and costs by enabling the production of photovoltaic modules with fully cross-linked resin layers, maintaining the same properties as standard modules while optimizing the manufacturing process.
Implementation Method 1
using blocked isocyanates that are activated by temperature, allowing for faster and more controlled cross-linking
Implementation Method 2
partial cross-linking of the layer of coating resin
Data Source
AI summary
According to the present invention, a method for forming a photovoltaic module is disclosed, the photovoltaic module comprising an intermediate film for a backsheet for photovoltaic modules comprising a substrate film, for example, a PET film, and a partially cross-linked layer of coating resin. The method includes providing a substrate film, depositing and spreading a layer of coating resin on the substrate film, and partially cross-linking the layer of coating resin. According to this method, the cross-linking of the resin is stopped before it is completed so that the intermediate film is obtained, and it is finished during the subsequent process of laminating the intermediate film to the encapsulant of a photovoltaic module.