Composite Encapsulating Material for High-Insulation PV Module Edges
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Solution Overview
Problem
Existing encapsulating materials for photovoltaic modules, such as POE and EVA, suffer from long curing times, low capacity utilization, and poor insulation performance, leading to increased material consumption and weight due to the need for a wide electrical safety distance between charged bodies and metal frames.
Innovation Solution
A composite encapsulating material comprising high insulation materials like polyimide, modifiers, and anti-aging agents, which provide excellent insulation performance, transparency, and fast crosslinking, reducing the distance between charged bodies and frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional encapsulating materials like EVA or POE are used, then the module can be manufactured with existing processes, but the insulation performance is poor requiring larger electrical safety distances which increases material consumption and weight
Solution Approach 1:
The patent changes the material parameters by using polyimide base resin with specific glass transition temperature (180-220℃) and intrinsic viscosity (0.6-1.2 dl/g) to achieve high insulation performance. The bulk resistivity reaches 1×10^17 Ω·cm and breakdown voltage reaches 80KV/mm, allowing reduction of electrical safety distances and thus reducing material consumption.
Solution Approach 2:
The patent creates a composite encapsulating material system by combining polyimide base resin with specific modifiers (polyperfluoroethylene propylene, tetramethyldisiloxane, fluorine-containing linear polyimide) to achieve both high insulation performance and appropriate processing characteristics, resolving the contradiction between performance and material usage.
2Productivity
If conventional encapsulating materials like EVA or POE are used, then the manufacturing process is simple, but the curing time is long and lamination cycle is extended which reduces productivity
Solution Approach 1:
The patent optimizes the viscosity parameter of the encapsulating material to 10-100 Pa·s at processing temperature, which enables fast lamination and reduces curing time. The specific composition with modifiers achieves rapid crosslinking while maintaining high insulation performance, thus improving productivity without sacrificing material efficiency.
3Reliability
If larger electrical safety distances are maintained to ensure insulation, then safety is improved, but the blank area at module edges increases which reduces capacity utilization
Solution Approach 1:
The patent achieves extreme insulation performance with bulk resistivity of 1×10^17 Ω·cm and breakdown voltage of 80KV/mm through controlled polymerization and specific compositional parameters. This allows minimizing the electrical safety distance to just 5mm while maintaining safety, thereby maximizing capacity utilization and reducing blank areas.
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 composite encapsulating material achieves a bulk resistivity of 1×10^17 Ω·cm and a breakdown voltage strength of 80KV/mm, minimizing material consumption and weight while maintaining safety, thus reducing the blank area and overall cost of photovoltaic modules.
Implementation Method 1
a working principle of photovoltaic modules is to convert solar energy into electrical energy based on a photovoltaic effect
Implementation Method 2
the high insulation material includes: 70-95 parts of polyimide, 1-10 parts of polyperfluoroethylene propylene, 2-10 parts of fluorine-containing linear polyimide, and 2-10 parts of tetramethyldisiloxane
Data Source
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AI summary
Provided is a composite encapsulating material and a photovoltaic module encapsulated with the composite encapsulating material, which relate to the technical field of photovoltaic modules. At least a partial area of the composite encapsulating material includes a high insulation material, and the high insulation material includes polyimide, modifier and modified polyimide. The above technical solution can improve an insulation performance of the encapsulating material, reduce a blank area of an edge of the module, reduce a weight of the photovoltaic module, and further reduce comprehensive cost of the photovoltaic module.