Coextruded Solar Panel Backsheet Adhesion
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Solution Overview
Problem
Current solar panel backsheets are prone to premature failure due to poor UV and hydrolysis resistance, high costs associated with fluoropolymer layers, and interlayer adhesion issues caused by adhesives, leading to inefficiencies and safety concerns.
Innovation Solution
A coextruded backsheet structure comprising an exterior polyamide and ionomer alloy layer, a middle talc-filled polyamide layer, and an interior polyamide and ionomer alloy layer, joined through a co-extrusion process without adhesives, providing enhanced weather resistance, durability, and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluoropolymer exterior layer is used to provide UV protection, then UV resistance and durability are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from fluoropolymer to polyamide, which provides comparable UV resistance through inherent polyamide chemistry and UV stabilizers, while significantly reducing material cost. The polyamide layer is formulated with specific additives to achieve the required UV protection without using expensive fluoropolymer materials.
Solution Approach 2:
The patent replaces expensive fluoropolymer with a more economical polyamide material that, while having a shorter theoretical lifespan, provides adequate UV protection for the required service life when properly formulated with stabilizers, thereby reducing manufacturing cost while maintaining acceptable reliability.
2Stability of the object's composition
If PET core layer is used for insulation and dimensional stability, then electrical insulation and dimensional stability are improved, but UV resistance and hydrolysis resistance deteriorate
Solution Approach 1:
The patent uses a composite polyamide material for the exterior layer that combines the benefits of dimensional stability with superior UV and hydrolysis resistance. The polyamide composite is formulated with specific additives and fillers to achieve both mechanical stability and environmental resistance, overcoming PET's weaknesses while maintaining its strengths.
Solution Approach 2:
The patent changes the material composition from PET to polyamide, fundamentally altering the chemical properties to achieve better UV and hydrolysis resistance while maintaining dimensional stability through proper formulation and processing of the polyamide material.
3Strength
If adhesive layers are used to bond backsheet layers, then interlayer adhesion is improved, but reliability deteriorates due to adhesion failures
Solution Approach 1:
The patent merges the bonding function into the extrusion process itself, where the backsheet layers are bonded together through heat and pressure during co-extrusion, eliminating the need for separate adhesive layers. This integration removes the adhesive interface that is prone to failure, while still achieving strong interlayer adhesion through direct material bonding.
Solution Approach 2:
The patent extracts and removes the adhesive layer from the backsheet structure, eliminating the source of adhesion failures. The bonding function is transferred to the extrusion process, where layers are directly bonded without requiring a separate adhesive material, thereby improving reliability by removing the weak link.
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 coextruded backsheet structure improves solar panel efficiency by up to 5%, extends panel lifespan, and reduces manufacturing costs by eliminating adhesive-related issues, while offering superior UV resistance and moisture management.
Implementation Method 1
a first polymer layer, a second polymer layer, and a third polymer layer are coextruded, without adhesives, into a laminated structure
Implementation Method 2
The exterior layer, middle layer, and interior layer are joined together through a co-extrusion process
Data Source
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AI summary
An improved backsheet used in the construction of solar panels is disclosed. A method of manufacturing the backsheet and solar panel comprises the backsheet including coextrusion processes are also disclosed. Additionally, a photovoltaic solar panel module comprising the backsheet of the invention is disclosed. The backsheet of the instant invention may comprise an exterior layer having inner and outer surfaces, a middle layer, having inner and outer surfaces, and an interior layer having inner and outer surfaces. In one embodiment of the invention, the outer surface of the middle layer may be adjoined lo the inner surface of the exterior layer, and the inner surface of the middle layer may be adjoined to the outer surface of the interior layer.