Ethylene-Vinyl Acetate Copolymer Crosslinking via Reactor Temperature Control
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Solution Overview
Problem
Ethylene-vinyl acetate copolymers exhibit low mechanical strength, which limits their performance as encapsulant materials for solar cell modules, despite their excellent transparency and adhesive properties.
Innovation Solution
An ethylene-vinyl acetate copolymer with a high degree of crosslinking is achieved by controlling the temperature difference and initiator input ratio in an autoclave reactor, even with a reduced amount of crosslinking agent, resulting in a copolymer with specific properties such as 89% or more crosslinking, 25-35% vinyl acetate content, and optimized viscosity ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If ethylene-vinyl acetate copolymer is used as encapsulant material, then transparency and adhesive properties are improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the temperature difference (ΔT = T1 - T2) in the autoclave reactor during polymerization. By optimizing reaction parameters including temperature gradient, initiator input ratio, and reaction zones, the copolymer achieves a degree of crosslinking of 89% or more, thereby improving mechanical strength while maintaining transparency and adhesive properties
Solution Approach 2:
The patent creates a crosslinked composite structure within the ethylene-vinyl acetate copolymer by controlling the polymerization process to achieve high crosslinking degree (89% or more). This crosslinked network structure enhances mechanical strength while preserving the inherent transparency and adhesive characteristics of the copolymer
2Stability of the object's composition
If autoclave reactor is used for polymerization, then uniform reaction temperature is improved, but mechanical strength of copolymer deteriorates
Solution Approach 1:
The patent segments the autoclave reactor into three or more reaction zones with different temperature characteristics. By dividing the reactor and controlling temperature in each zone (T1 > T2 > T3), the patent achieves both uniform temperature maintenance and high mechanical strength through optimized local reaction conditions
Solution Approach 2:
The patent applies local quality by creating different temperature conditions in different zones of the reactor. The temperature gradient (T1 > T2 > T3) across reaction zones allows optimization of polymerization conditions in each region, achieving high crosslinking degree and mechanical strength while maintaining overall temperature uniformity
3Ease of manufacture
If crosslinking agent amount is reduced, then process simplicity is improved, but degree of crosslinking deteriorates
Solution Approach 1:
The patent applies self-service by enabling the copolymer to self-crosslink through controlled polymerization conditions. By optimizing temperature difference (ΔT = T1 - T2) and initiator input ratio during autoclave reactor operation, the system achieves high crosslinking degree (89% or more) without requiring large amounts of external crosslinking agents, thereby simplifying the manufacturing process
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 resulting copolymer exhibits enhanced mechanical strength and adhesive properties, making it suitable for applications in solar cell modules and other protective films, while maintaining processability and transparency.
Implementation Method 1
polymerizing an ethylene monomer and a vinyl acetate monomer in an autoclave reactor in the presence of an initiator
Implementation Method 2
the reactor satisfies a relationship of a temperature (T1) of one or more reaction zones from the lowermost end>a temperature (T2) of one or more reaction zones from the uppermost end>a temperature (T3) of one or more reaction zones therebetween, and ΔT which is a difference between T1 and T2 satisfies 20° C. to 40° C.
Data Source
AI summary
Provided are an ethylene-vinyl acetate copolymer having a high degree of crosslinking by controlling a temperature difference in an autoclave reactor and an input ratio of an initiator during polymerization, even though a reduced amount of a crosslinking agent is used, and a preparation method thereof.