Coated Polyester Film Lamination with Oxazoline-Crosslinked EVA Adhesion
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Solution Overview
Problem
Existing technologies face challenges in achieving a strong and hydrolytically stable adhesive bond between polyester films and ethylene-vinyl acetate copolymer layers, particularly when exposed to high temperatures and humidity, and the addition of white pigment particles further complicates bonding.
Innovation Solution
A coating composition comprising an alkylene carboxylic copolymer, such as ethylene acrylic acid copolymer, combined with an oxazoline polymer cross-linking agent is applied to the polyester film, forming a bond with a cross-linkable ethylene-vinyl acetate copolymer layer, enhancing adhesion and maintaining bond strength under harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyester film is laminated to an ethylene-vinyl acetate copolymer layer, then environmental protection and electrical insulation are provided, but a strong and hydrolytically stable adhesive bond is difficult to achieve
Solution Approach 1:
A silane-modified polyethylene copolymer adhesive layer is introduced as an intermediary between the polyester film and the cross-linked EVA encapsulant. This adhesive layer contains silane groups that can form covalent bonds with both the polyester substrate and the EVA, creating a stable bridge that resists hydrolysis while maintaining strong adhesion.
Solution Approach 2:
The adhesive layer undergoes cross-linking transformation when exposed to moisture, where silane groups hydrolyze and condense to form a three-dimensional cross-linked network. This parameter change from linear to cross-linked structure enhances both the bond strength and hydrolytic stability of the interface.
2Illumination intensity
If white pigment particles are added to polyester film, then optical properties are improved, but bonding ability is reduced
Solution Approach 1:
The silane-modified polyethylene copolymer adhesive acts as a mediator that can wet and adhere to both the pigmented polyester surface and the EVA encapsulant. The adhesive's flexible polymer chains can penetrate and bind to pigment particles, maintaining bonding ability despite the presence of white pigment particles in the polyester film.
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 coating provides excellent initial bond strength and retains a significant portion of its strength even after exposure to high temperatures and humidity, effectively bonding polyester films with ethylene-vinyl acetate copolymers and films containing white pigment particles.
Implementation Method 1
A coating composition comprising an alkylene carboxylic copolymer, such as ethylene acrylic acid copolymer, combined with an oxazoline polymer cross-linking agent is applied to the polyester film
Implementation Method 2
The coating provides excellent initial bond strength and retains a significant portion of its strength even after exposure to high temperatures and humidity, effectively bonding polyester films with ethylene-vinyl acetate copolymers
Implementation Method 3
achieves a strong and hydrolytically stable adhesive bond between the polyester film and ethylene-vinyl acetate copolymer layer, particularly when exposed to high temperatures and humidity
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
A bonding material is described that is well suited to bonding polymer films, such as polyester films, to other substrates. In one embodiment, for instance, the bonding material can be used to bond a polyester film to a layer containing an ethylene-vinyl acetate copolymer to form a backing material for a photovoltaic device. The bonding material generally comprises a polymer component combined with a cross-linking agent. The polymer component may comprise an alkylene carboxylic acid copolymer, such as an ethylene acrylic acid copolymer or an ethylene methacrylic acid copolymer. In an alternative embodiment, the polymer component may comprise a phenoxy resin. The cross-linking agent, on the other hand may comprise an oxazoline polymer.