Crosslinked Polyethylene Backsheet for Photovoltaic Modules

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing backsheet layers for photovoltaic modules face challenges with high cost, limited insulation resistance, hydrolysis, and high water vapor transmission rates, leading to complex manufacturing processes and potential delamination issues, while also risking penetration by solder peaks during lamination.

Innovation Solution

A crosslinked polymer composition comprising ethylene with functional groups and silane units, which provides enhanced heat resistance and mechanical properties, allowing for reduced layer thickness and improved deformation resistance, achieved through silane crosslinking via hydrolysable silane compounds and silanol condensation catalysts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multilayer structures with adhesive layers are used to compensate for limited insulation resistance and hydrolysis, then reliability is improved, but device complexity increases and manufacturing precision deteriorates due to delamination risks

Engineering Contradiction:

Improveinsulation resistanceVSAvoidmultilayer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (insulation, hydrolysis resistance, mechanical strength) into a single crosslinked polyethylene layer, eliminating the need for separate adhesive layers and reducing delamination risks while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses crosslinked polyethylene as a composite material that integrates multiple protective functions (insulation resistance, hydrolysis resistance, mechanical strength) into one layer, replacing complex multilayer structures

Inventive Principle:

Principle #40Composite materials

2Reliability

If multilayer structures are used to improve insulation properties, then reliability is improved, but ease of manufacture deteriorates due to complicated manufacturing processes

Engineering Contradiction:

Improveinsulation resistanceVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple protective functions into a single crosslinked polyethylene layer, simplifying the manufacturing process by eliminating the need to handle and assemble multiple separate layers with adhesive interfaces

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If layer thickness is reduced to prevent solder peak penetration, then productivity is improved, but strength deteriorates

Engineering Contradiction:

Improvelamination processVSAvoidmechanical strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent changes the physical and chemical parameters of the polyethylene layer through crosslinking, which fundamentally alters the material's thermal and mechanical properties, enabling thin layers to maintain high strength and heat resistance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The crosslinking process creates a network structure that fundamentally changes the polymer's phase behavior and thermal properties, allowing the material to maintain dimensional stability and strength at elevated temperatures despite reduced thickness

Inventive Principle:

Principle #36Phase transitions

4Strength

If crosslinking is used to improve heat resistance and mechanical properties, then strength is improved, but ease of manufacture deteriorates due to additional crosslinking steps

Engineering Contradiction:

Improveheat resistanceVSAvoidcrosslinking process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent incorporates silane groups into the polyethylene structure during polymerization, preparing the material in advance for crosslinking, so that the crosslinking activation later proceeds easily with minimal additional processing steps

Inventive Principle:

Principle #10Preliminary action

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 offers superior heat resistance, mechanical properties, and deformation resistance, maintaining layer thickness and tensile strength, even at elevated temperatures, and enables the production of backsheet elements with reduced thickness, as demonstrated by improved performance in distance through insulation tests.

Implementation Method 1

silane crosslinking via hydrolysable silane compounds and silanol condensation catalysts

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

silane crosslinking via hydrolysable silane compounds and silanol condensation catalysts

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

polymer of ethylene (a) which bears functional group(s) containing units; and silane group(s) containing units (b); wherein the polymer (a) is crosslinked via the silane group(s) containing units (b)

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentEP3345222B1Polyethylene composition for a layer element of a photovoltaic module

Publication Date: 2023.06.21 BOREALIS AG

Figure 1

AI summary

The invention relates to a backsheet element for a photovoltaic module comprising at least one layer, which comprises a crosslinked polymer composition, which comprises a polymer of ethylene, to a photovoltaic module comprising at least one photovoltaic element and the backsheet element of the invention and to the use of the crosslinked polymer composition for producing at least one layer of a backsheet element of the invention for a photovoltaic module.