Dual-Cure Lacquer Transfer Coating for Solar Cell Modules
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Solution Overview
Problem
Conventional transparent protective films used in solar cell modules degrade over time, losing mechanical resistance and weather resistance, leading to reduced lifespan due to heat exposure and plasticizer loss.
Innovation Solution
A method involving the application of a dual-cure lacquer as a transparent protective layer, which is initially flexible and thermally pre-hardened, then fully cured with UV light, providing enhanced mechanical resistance and flexibility, applied using a transfer coating process to minimize solvent contamination and ensure uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plastic films are used as transparent protective substrates, then flexibility and ease of application are improved, but mechanical resistance and weather resistance deteriorate over time due to heat exposure and plasticizer loss
Solution Approach 1:
The patent uses a composite structure consisting of a plastic film substrate combined with a lacquer layer. The plastic film provides flexibility and ease of application, while the lacquer layer (comprising components A, B, and C) provides enhanced mechanical resistance and weather resistance. This composite approach allows both requirements to be satisfied simultaneously.
Solution Approach 2:
The patent applies parameter changes by using a lacquer that can be cured through UV irradiation or heating. The lacquer transitions from a liquid state (easy to apply) to a solid crosslinked network structure (high mechanical resistance). This phase transition and chemical transformation resolve the contradiction between ease of application and mechanical strength.
2Ease of operation
If plastic films are used as transparent protective substrates, then flexibility is improved, but durability and life expectancy deteriorate due to loss of plasticizers and reduced weather resistance
Solution Approach 1:
The patent combines a plastic film with a specially formulated lacquer layer that contains weather-resistant components. The lacquer acts as a protective barrier that prevents plasticizer loss and protects against environmental degradation, thereby improving durability while maintaining the flexibility provided by the plastic film substrate.
Solution Approach 2:
The lacquer undergoes chemical transformation through UV curing or thermal treatment, forming a crosslinked polymer network that is highly resistant to weathering. This parameter change from liquid to cured state provides long-term durability without compromising the underlying film's flexibility.
3Strength
If a transparent protective layer is applied to protect the photovoltaic layer, then mechanical protection is improved, but the complexity of the production process increases
Solution Approach 1:
The patent applies the lacquer to the photovoltaic layer in advance, before final assembly. The lacquer is applied as a flexible layer composite that can be easily handled and positioned. This preliminary action simplifies the overall production process by combining protection application with assembly steps.
Solution Approach 2:
The patent replaces complex mechanical protection systems with a chemical solution - the lacquer layer that provides mechanical protection through its cured structure. This substitution simplifies the production process by using a straightforward coating and curing operation instead of more complex mechanical assembly steps.
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 dual-cure lacquer layer offers improved mechanical resistance, flexibility, and weather stability, extending the lifespan of solar cell modules while maintaining transparency and ease of application.
Implementation Method 1
the paint is at least partially, preferably completely, irreversibly hardened by irradiation with UV light or by heating or by a combination of both
Implementation Method 2
the paint is at least partially, preferably completely, irreversibly hardened by irradiation with UV light or by heating or by a combination of both
Data Source
AI summary
The invention relates to a method for producing a solar cell module, according to which a photovoltaic layer is applied to a backsheet and is covered by a transparent layer. In order to apply the layer, a flexible layer composite with a temporary backing film that has a varnish layer is provided, the side of said layer composite provided with the varnish layer is pressed onto the photovoltaic layer and the temporary backing film is removed, leaving the varnish layer as a transparent layer on the photovoltaic layer. The invention also relates to a solar cell module comprising a transparent layer consisting of a cured varnish and to the use of a varnish for the production of a solar cell module of this type.