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

VSEngineering Contradiction Analysis

1Reliability

If an insulating sheet is used in solar cell modules, then insulating performance is improved, but adhesion stability becomes insufficient

Engineering Contradiction:
Improveinsulating performanceVSAvoidadhesion stability
Core Design Contradiction:
ReliabilityVSStability of the object's composition

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.

Inventive Principle:
Principle #40Composite materials

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.

Inventive Principle:
Principle #1Segmentation

2Strength

If adhesion strength is increased, then bonding between components is improved, but insulating performance deteriorates

Engineering Contradiction:
Improveadhesion strengthVSAvoidinsulating performance
Core Design Contradiction:
StrengthVSReliability

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #40Composite materials

Data Source

PatentEP3357987B1Insulating multilayer sheet and solar cell module
Publication Date: 2021.02.17 DOW MITSUI POLYCHEMICALS CO LTD
  • EP3357987B1 patent drawingFigure 1~2
  • EP3357987B1 patent drawingFigure 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.