Frameless Solar Assembly Adhesive Tape for Weatherproof Edge Sealing

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Solution Overview

Problem

Existing solar assemblies require aluminum frames for protection, which increase weight and cost, and have complex mounting operations, making them unsuitable for applications like photovoltaic curtain walls and street lamps where a frameless solution is needed.

Innovation Solution

A frameless adhesive tape with a substrate layer, optional adhesive layers, a primer layer, and a film layer providing aging-resistant and weather-resistant properties, which can seal the edges of solar assemblies, reducing weight, production time, and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If aluminum alloy frame is used to seal and protect solar assemblies, then the assemblies have good structural strength and protection, but the weight and cost of the assemblies increase

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces the rigid aluminum alloy frame with a flexible adhesive tape that has a thin film structure. The adhesive tape includes a substrate layer with adhesive layers that can seal and protect the edges of solar assemblies without the weight and complexity of metal frames, while still providing adequate structural support for frameless applications.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The adhesive tape is a cost-effective alternative to aluminum frames, using simpler materials and manufacturing processes that reduce both material costs and production costs, making it suitable for applications where extreme structural strength is not required.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If aluminum alloy frame is used to seal solar assemblies, then the assemblies have good protection, but the mounting operation becomes complex

Engineering Contradiction:

ImproveprotectionVSAvoidmounting operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The flexible adhesive tape can be easily applied to the edges of solar assemblies without requiring complex mounting operations. The adhesive nature of the tape allows for simple application compared to the assembly and fastening required for aluminum frames, while still providing reliable protection.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If aluminum alloy frame is used for solar assemblies, then the assemblies have good durability, but the manufacturing cost increases

Engineering Contradiction:

ImprovedurabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The adhesive tape uses cheaper materials and simpler manufacturing processes compared to aluminum alloy frames. The tape can be produced through coating and drying processes rather than metal forming and assembly, significantly reducing manufacturing costs while providing adequate durability for frameless solar applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Weight of moving object

If adhesive tape is used to seal solar assembly edges, then the weight and cost are reduced, but the weather resistance and aging resistance must be maintained

Engineering Contradiction:

ImproveweightVSAvoidweather resistance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The adhesive tape uses composite material structure with a substrate layer and adhesive layers that provide both lightweight properties and weather resistance. The multi-layer composite structure ensures durability against weathering and aging while maintaining the weight reduction benefits, eliminating the need for heavy aluminum frames.

Inventive Principle:

Principle #40Composite 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

The adhesive tape effectively seals solar assembly edges, offering superior weather resistance, abrasion resistance, and reduced production time without the need for curing, while maintaining the assembly's functionality and appearance over extended outdoor exposure.

Implementation Method 1

an adhering layer for adhesion and cushioning, which is used to contact the edge of an article

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

an aging-resistant protective layer on the adhering layer... a film layer, which is situated on the primer layer

Methodology Applied

Scientific EffectWeathering resistance: Weathering

Data Source

PatentEP2675857B1Adhesive tape and solar assembly and article made thereof

Publication Date: 2020.01.22 3M INNOVATIVE PROPERTIES CO

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AI summary

The invention provides a frameless photo-energy assembly including a photo-energy converter, wherein an edge of the photo-energy converter is sealed by an adhesive tape, comprising an adhering layer for adhesion and cushioning; and an aging-resistant protective layer. The adhering layer is used to contact the edge of an article and comprises: a substrate layer; optionally, a first adhesive layer and a second adhesive layer situated at both sides of the substrate layer oppositely, wherein the first adhesive layer being used to be contact with the article. The aging-resistant protective layer is situated on the adhering layer, which comprises: an optional primer layer, which is situated on the adhering layer; and a film layer, which is situated on either the primer layer or the substrate or the second adhesive layer. The invention further provides an adhesive tape for sealing an edge of an article and an article made of the assembly.