Interlayer Resin Composition With Controlled Crosslinking Rate
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Solution Overview
Problem
Conventional laminated glass interlayer films and solar cell encapsulants formed from ethylene-unsaturated ester copolymers and crosslinking agents lack satisfactory optical characteristics and moisture-resistant adhesiveness, especially under high humidity conditions.
Innovation Solution
A resin composition with a controlled crosslinking rate, measured by the torque values T10, T50, and T100 at 130°C using a moving die rheometer, is developed, with a crosslinking rate index of (T50−T10)/(Y−X) between 0.01 dN·m/min and 0.25 dN·m/min, incorporating an ethylene-unsaturated ester copolymer and an organic peroxide crosslinking agent, to balance optical characteristics and moisture-resistant adhesiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crosslinking rate of the resin composition is increased to improve mechanical strength and heat resistance, then the optical characteristics deteriorate and moisture-resistant adhesiveness decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the crosslinking rate within a specific range (0.01-0.25 dN·m/min) to achieve optimal balance between mechanical strength and moisture-resistant adhesiveness. This resolves the contradiction by finding the optimal parameter value that satisfies both requirements simultaneously rather than maximizing one at the expense of the other.
Solution Approach 2:
The patent uses a composite resin composition containing ethylene-unsaturated ester copolymer and crosslinking agent, where the interaction between these components creates a crosslinked network structure. By controlling the crosslinking rate parameter, the composite material achieves both high mechanical strength and good moisture-resistant adhesiveness, resolving the technical contradiction between these two properties.
2Temperature
If the crosslinking rate is increased to improve heat resistance, then optical characteristics such as transparency and haze performance worsen
Solution Approach 1:
The patent resolves this contradiction by changing and controlling the crosslinking rate parameter within a specific range. This controlled parameter change allows the material to achieve sufficient heat resistance while maintaining good optical characteristics, avoiding the deterioration that occurs with excessive crosslinking.
Solution Approach 2:
The patent applies partial action by using a moderate crosslinking rate (0.01-0.25 dN·m/min) rather than maximum crosslinking. This partial crosslinking is sufficient to provide the required heat resistance while avoiding the excessive crosslinking that would cause optical deterioration, thus resolving the contradiction between heat resistance and optical characteristics.
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 resin composition achieves an excellent performance balance between optical characteristics and moisture-resistant adhesiveness, reducing bubble formation and improving mechanical and thermal properties of laminated glass and solar cell encapsulants.
Implementation Method 1
a film formed from an ethylene-unsaturated ester copolymer and a crosslinking agent
Implementation Method 2
the organic peroxide is a peroxyketal represented by a specific chemical formula and having a 10-hour half-life at a temperature of 100° C. or less
Data Source
AI summary
A resin composition for a laminated glass interlayer film or a solar cell encapsulant contains an ethylene-unsaturated ester copolymer (A) and a crosslinking agent (B). When the torque of the resin composition is measured over time at 130° C. using a moving die rheometer, the torque value 60 minutes after the start of measurement is defined as T100 [dN·m], the torque value of 10% of T100 is defined as T10, the torque value of 50% of T100 is defined as T50, the minimum torque value during measurement is defined as Tmin, the time to reach T10 from the start of measurement is defined as X [min], and the time to reach T50 from the start of measurement is defined as Y [min], the crosslinking rate represented by (T50−T10)/(Y−X) (where T50=(100−Tmin)×0.5+Tmin, T10=(T100−Tmin)×0.1+Tmin) exceeds 0.01 dN·m/min and 0.25 dN·m/min or less.