Edge Protected Barrier Assemblies for Flexible Solar Devices
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Solution Overview
Problem
Existing flexible barrier films for solar devices face challenges with edge delamination, which affects their durability and performance, especially when exposed to light and stress in outdoor environments.
Innovation Solution
A multilayer film assembly comprising a barrier stack adjacent an electronic device, a weatherable sheet opposite the device, and protective layers to control exposure to light and stress, reducing delamination by less than 20 grams/inch through careful assessment and modification of light, water, and stress inputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass is used as encapsulating material for solar devices, then barrier properties against water vapor and UV stability are improved, but weight increases, brittleness increases, and flexibility decreases
Solution Approach 1:
The patent changes the material parameters from traditional glass to flexible polymer films with modified compositions (e.g., polyesters, polyamides, fluoropolymers) that achieve comparable barrier properties while providing flexibility and reduced weight. The multilayer structure with specific thickness parameters (total thickness 1-50 micrometers) optimizes the balance between barrier performance and mechanical flexibility.
Solution Approach 2:
The patent employs composite multilayer film structures combining different polymer materials (e.g., PET, PA, PVF, EVOH layers) to achieve synergistic effects where each layer contributes specific properties: barrier performance, UV stability, flexibility, and adhesion. This composite approach replicates glass-like protection while eliminating its drawbacks.
2Reliability
If flexible barrier films are made as multi-layer film laminates to approach glass-like barrier properties, then barrier performance is improved, but delamination risk increases
Solution Approach 1:
The patent introduces intermediary adhesion promotion layers between the different film layers in the multilayer laminate. These intermediary layers (such as primer coatings or adhesive layers) mediate the bonding between layers with different surface energies, preventing delamination while maintaining the overall barrier performance of the composite structure.
Solution Approach 2:
The patent applies different surface treatments and adhesive properties to specific local regions of the film layers, particularly at the interfaces between layers. Edge sealing treatments and localized adhesion promotion ensure that the most vulnerable regions (edges and interfaces) have enhanced bonding strength to prevent delamination.
3Reliability
If edge delamination is reduced through control of light, water, and stress inputs, then durability is improved, but device complexity increases
Solution Approach 1:
The patent incorporates preliminary protective measures during the manufacturing process, such as pre-applied edge sealants, pre-formed adhesion promotion layers, and pre-stressed mounting configurations that anticipate and prevent delamination before it occurs. This preliminary action reduces the need for complex operational controls and maintenance.
Solution Approach 2:
The patent converts potentially harmful environmental factors (light, moisture, stress) into beneficial effects by using UV-stabilized polymer materials that leverage light exposure to maintain their protective properties, and by designing hygroscopic layers that use moisture absorption to reduce thermal stress and prevent delamination.
Data Source
AI summary
The present application is directed to an assembly comprising an electronic device, and a multilayer film. The multilayer film comprises a barrier stack adjacent the electronic device; and a weatherable sheet adjacent the barrier stack opposite the electronic device. The assembly additionally comprises a protective layer in contact with the electronic device and the weatherable sheet. The present application allows for the combination of any of the disclosed elements.