Insulating Multilayer Sheet for Solar Cell Modules
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Solution Overview
Problem
Existing insulating sheets used in solar cell modules lack a balance between adhesion stability and insulating performance, with insufficient adhesion stability and insulating performance simultaneously.
Innovation Solution
A multilayer sheet comprising an electrically insulating resin film layer and an adhesive layer with an epoxy group-containing ethylene-based copolymer and a specific ethylene-based copolymer, such as ethylene/polar monomer or ethylene/α-olefin copolymer, is used to enhance adhesion stability and insulating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sheet is used in solar cell modules, then insulating performance is improved, but adhesion stability becomes insufficient
Solution Approach 1:
The patent applies composite materials by combining an electrically insulating resin film layer with an adhesive layer containing specific polymers (epoxy group-containing ethylene-based copolymer and ethylene-based copolymer). This composite structure simultaneously provides both insulating performance from the resin film layer and adhesion stability from the adhesive layer, resolving the contradiction between these two properties.
Solution Approach 2:
The insulating sheet is segmented into multiple functional layers: an electrically insulating resin film layer for providing insulation and an adhesive layer for providing adhesion stability. This segmentation allows each layer to specialize in one function, enabling the overall sheet to achieve both insulating performance and adhesion stability simultaneously.
2Strength
If adhesion strength is increased, then bonding between components is improved, but insulating performance deteriorates
Solution Approach 1:
The sheet is divided into distinct layers where the adhesive layer provides adhesion strength and the electrically insulating resin film layer provides insulating performance. This segmentation prevents the trade-off by assigning each function to a separate layer that does not compromise the other property.
Solution Approach 2:
The composite structure combines materials with different primary functions: the adhesive layer uses polymers optimized for bonding strength while the resin film layer uses materials optimized for electrical insulation. This composite approach allows both adhesion strength and insulating performance to be maximized simultaneously without compromise.
Data Source
Figure 1~2
Figure 3
AI summary
An insulating multilayer sheet (10) includes: an electrically insulating resin film layer (15); and an adhesive layer (20) that is provided on a single surface or both surfaces of the electrically insulating resin film layer (15). The adhesive layer (20) includes an epoxy group-containing ethylene based copolymer (A) and at least one ethylene based copolymer (B) (excluding the epoxy group-containing ethylene based copolymer (A)) selected from the group consisting of an ethylene/polar monomer copolymer and an ethylene/α-olefin copolymer having a density of 920 kg/m3 or lower.