Foaming Agent Encapsulation for Optoelectronic Components
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Solution Overview
Problem
The existing methods for encapsulating optoelectronic components are time- and energy-consuming, and attempts to speed up the lamination process have not gained market acceptance, while also requiring costly and risky investments in new materials and equipment.
Innovation Solution
A method involving embedding optoelectronic components between a first transparent polymer layer and a second polymer layer filled with non-activated foaming agent, where the foaming agent, consisting of microspheres with a polymer membrane enclosing a blowing agent, is activated to weld the polymer layers together, ensuring secure encapsulation with minimal displacement of the components during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lamination process is used for encapsulating optoelectronic components, then reliable encapsulation is achieved, but the process is time-consuming and energy-intensive
Solution Approach 1:
The patent changes the physical-chemical parameters of the polymer layers by introducing a foaming agent that transforms the material state during processing. The polymer composition is modified to include expandable microballoons that change from compressed to expanded state, enabling faster encapsulation while maintaining reliability through the resulting foam structure that provides both sealing and mechanical protection.
Solution Approach 2:
The patent utilizes phase transition of the foaming agent from compressed to expanded state during heating. This phase change allows the polymer layers to expand and bond quickly, reducing encapsulation time while the resulting foam structure ensures reliable protection against water vapor and oxygen ingress.
2Reliability
If traditional lamination process is used for encapsulating optoelectronic components, then reliable encapsulation is achieved, but energy consumption increases
Solution Approach 1:
The patent modifies the thermal parameters of the process by using a foaming agent that activates at specific temperatures. This allows the encapsulation to proceed at lower temperatures for shorter durations, reducing energy consumption while the foam structure formed during this process ensures reliable encapsulation against environmental factors.
Solution Approach 2:
The patent exploits the phase transition of the foaming agent that occurs at controlled temperatures. This phase change enables the polymer to expand and bond efficiently at lower energy inputs compared to traditional lamination, reducing overall energy consumption while maintaining encapsulation reliability through the foam structure.
3Reliability
If existing encapsulation methods for solar cells are used, then reliable encapsulation is achieved, but the process is slow and costly
Solution Approach 1:
The patent changes the rheological parameters of the polymer by incorporating a foaming agent that alters the material's flow and bonding characteristics. This enables faster encapsulation speeds while the resulting foam structure maintains reliability by providing effective sealing and mechanical protection without requiring prolonged processing times.
Solution Approach 2:
The patent utilizes the phase transition of the foaming agent to accelerate the encapsulation process. The rapid expansion of the foam structure during controlled heating enables faster bonding of polymer layers, increasing productivity while the foam's cellular structure ensures reliable protection against water vapor and oxygen ingress.
4Object-affected harmful factors
If polymer layers are used for encapsulation, then protection against water vapor and oxygen is provided, but the process requires auxiliary adhesives and edge trimming
Solution Approach 1:
The patent changes the surface properties and bonding parameters of the polymer layers by using a foaming agent that creates a foam structure with enhanced adhesion characteristics. This allows the polymer layers to bond directly to the optoelectronic components without requiring auxiliary adhesives, and the foam structure provides effective sealing against water vapor and oxygen ingress.
Solution Approach 2:
The patent exploits the phase transition of the foaming agent to eliminate the need for auxiliary adhesives and edge trimming. The rapid expansion and bonding of the foam structure during heating creates self-sealing encapsulation that protects against water vapor and oxygen ingress without requiring additional processing steps or materials.
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
This method allows for rapid and secure encapsulation of optoelectronic components with established materials and methods, reducing the need for costly investments and minimizing the risk of component displacement, while providing a stable seal that eliminates the need for edge trimming and auxiliary adhesives.
Implementation Method 1
the foaming agent is activated, so that the two polymer layers connect to each other, in particular welded together and the components are enclosed between the two polymer layers
Implementation Method 2
the foaming agent is activated, so that the two polymer layers connect to each other
Implementation Method 3
The transparent polymer layer preferably has a transmission of more than 60%, in particular a transmission of more than 90% at a wavelength of 350 to 1150 nm
Implementation Method 4
the polymer layers connect to each other, in particular welded together
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The method comprises imbedding a component to be encapsulated between a first transparent polymer layer (2) and a second polymer layer, which is filled with non activated foaming agent and subsequently activating the foaming agent so that the polymer layers are welded with one another and the components are embedded between the polymer layers. The foaming agent is a microballoon that consists of polymer membrane that surrounds a drive means. An additional layer is arranged externally on the free side of the first polymer layer and/or the second polymer layer. The method comprises imbedding a component to be encapsulated between a first transparent polymer layer (2) and a second polymer layer, which is filled with non activated foaming agent and subsequently activating the foaming agent so that the polymer layers are welded with one another and the components are embedded between the polymer layers. The foaming agent is a microballoon that consists of polymer membrane that surrounds a drive means. An additional layer is arranged externally on the free side of the first polymer layer and/or the second polymer layer and comprises a water steam permeability of less than 200 g/m 2>/24 hours at 37.8[deg] C and 90% humidity and humidity and oxygen permeability of less than 20 cm 3>/24 hours at 23[deg] C and 50% humidity. The first transparent polymer layer has a transmission of greater than 90% on the wavelength of 350-1150 nm. The first polymer layer has a layer thickness of 50-300 mu m. The second polymer layer filled with foaming agent has a specific gravity of less than 700 kg/m 3>. The first and/or the second polymer layer is present on an anti-adhesively mounted auxiliary carrier. A transparent layer out of glass or UV-stabilized and weather-stabilized plastic with slight water steam permeability is mounted above the first polymer layer as additional layer and/or a layer out of glass or multi-layered UV-stabilized and weather-stabilized plastic foil with slight water steam permeability is mounted below the second polymer layer as additional layer. The second polymer layer exists in the form of a cover. The product to be encapsulated is arranged over the second polymer layer. The first transparent polymer layer exists in the form of a transparent cover (1). The foaming agent is induced under vacuum under a press. The first transparent polymer layer on the transparent cover, the component to be encapsulated and the second polymer layer filled with non-activated foaming agent on the further cover are guided in a roller column of a roller laminator. The transparent cover and the further cover pass directly over the rollers and the component to be encapsulated is brought between the polymer layers. The foaming of the foaming agent is carried out in the roller column so that the polymer layers are welded together and the components are imbedded between the polymer layers. The second polymer layer is brought on the further cover in the roller column of the roller laminate. The transparent cover and the further cover run directly over the rollers.