Flexible Photovoltaic Laminate UV Yellowing Prevention

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Solution Overview

Problem

Existing photovoltaic modules face issues with conversion efficiency loss due to yellowing of encapsulation resins like EVA or epoxy when exposed to UV radiation, and they lack sufficient resistance to shocks and deformations.

Innovation Solution

A flexible laminate photovoltaic module is designed with a front encapsulation layer comprising glass fiber fabric and a polyolefin-based resin, which prevents yellowing, and a rear encapsulation layer with glass fiber fabric and a second resin, enhancing impact resistance and integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ethylene-vinyl acetate (EVA) or epoxy resins are used to encapsulate photovoltaic cells, then the photovoltaic cells are protected mechanically and from external conditions, but the encapsulation resin yellows due to UV radiation exposure, reducing conversion efficiency

Engineering Contradiction:

Improveprotection of photovoltaic cellsVSAvoidconversion efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The encapsulation system is divided into multiple functional layers: a front encapsulation layer using polyolefin resin specifically designed to resist UV radiation and prevent yellowing, and a rear encapsulation layer that provides mechanical protection. This segmentation allows each layer to specialize in its primary function, with the front layer protecting against degradation and the rear layer providing structural support.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the chemical composition parameter of the encapsulation resin from traditional EVA or epoxy to polyolefin-based resin. This parameter change fundamentally alters the material's resistance to UV radiation, preventing the yellowing phenomenon and maintaining high conversion efficiency over time while preserving mechanical protection properties.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If polyolefin encapsulation resin is used to prevent yellowing, then conversion efficiency is maintained, but resistance to shocks and deformations is insufficient

Engineering Contradiction:

Improveconversion efficiencyVSAvoidresistance to shocks and deformations

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The patent creates a composite encapsulation structure combining polyolefin resin with glass fiber fabric. The polyolefin provides UV resistance and prevents yellowing, while the glass fiber reinforcement adds mechanical strength and resistance to shocks and deformations. This composite approach allows the material to simultaneously achieve chemical stability against UV radiation and mechanical durability.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If the photovoltaic module is made thin to reduce weight and size, then it can be integrated into lightweight structures, but the structural resistance and durability are reduced

Engineering Contradiction:

Improveweight of photovoltaic moduleVSAvoidstructural resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent employs thin-film encapsulation layers made of polyolefin resin that provide sufficient protection while maintaining minimal thickness. These thin films deliver both mechanical protection and UV resistance without adding significant weight, enabling the photovoltaic module to be integrated into lightweight and flexible applications while retaining structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

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 maintains high conversion efficiency and ensures the physical integrity of the photovoltaic module over time by preventing yellowing and enhancing shock resistance.

Implementation Method 1

polyolefins do not yellow as they are exposed to ultraviolet radiation

Methodology Applied

Scientific EffectUV radiation resistance:

Implementation Method 2

the combination of the encapsulation resin with a glass fiber fabric for the front and rear encapsulation layers makes it possible to give the laminate impact resistance

Methodology Applied

Scientific EffectImpact resistance:

Data Source

PatentEP3853910B1Flexible laminate of photovoltaic cells and associated production method

Publication Date: 2025.06.04 TOTALENERGIES SE

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Figure 5~6

AI summary

The present invention relates to a flexible laminate (1) of photovoltaic cells, comprising at least: - a layer of photovoltaic cells (3) connected together, and - a front layer (5) and a rear layer (7) for encapsulating the layer of photovoltaic cells (3), said front (5) and rear (7) encapsulating layers taking the layer of photovoltaic cells (3) in a sandwich, the front encapsulating layer (5) comprises at least one glass fibre fabric (51) and at least one first encapsulation resin (53) comprising at least one polyolefin, and the rear encapsulating layer (7) comprises at least one glass fibre fabric (71) and a second encapsulating resin (73). The present invention also relates to a method for producing such a flexible laminate (1).