Ionomeric Solar Cell Encapsulant Adhesion Stability
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Solution Overview
Problem
Conventional solar cell encapsulant layers, particularly those based on ethylene vinyl acetate (EVA), face issues with low adhesion to other components, creep resistance, and light stability, necessitating the use of adhesion primers and stabilizers, which complicates the production and lamination processes.
Innovation Solution
A solar cell module comprising a first encapsulant layer with a thickness of 0.1 to 20 mils, made from an ionomeric composition containing polymerized residues of α-olefins and 18 to 25 wt% α,β-ethylenically unsaturated carboxylic acid, which provides enhanced adhesion and stability without the need for adhesion primers, and an optional second encapsulant layer with the same composition, laminated to the solar cell layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If EVA compositions are used as encapsulant layers, then the encapsulant provides basic protective functions, but adhesion to other components is low and creep resistance is poor
Solution Approach 1:
The patent changes the chemical composition parameters by using ionomeric polymers with specific metal ion content (0.1-5 mmol/g) and molecular weight ranges, transforming the encapsulant material from conventional EVA to ionomeric compositions that inherently provide both strong adhesion and creep resistance without requiring additional additives
Solution Approach 2:
The patent employs composite ionomeric polymer structures combining organic polymer chains with inorganic metal ions (such as zinc, calcium, or aluminum) to create a material that exhibits both adhesive properties through metal coordination and structural stability through the composite architecture, resolving the contradiction between adhesion and creep resistance
2Strength
If adhesion primers and stabilizer packages are added to EVA compositions to overcome adhesion and stability issues, then adhesion and weathering resistance improve, but the sheet production and lamination processes become complicated
Solution Approach 1:
The patent extracts and eliminates the need for separate adhesion promoters and stabilizer packages by incorporating adhesion and stability functions directly into the ionomeric polymer structure itself, where the metal ions provide both adhesion mechanisms and inherent stabilization, thereby simplifying the production process
Solution Approach 2:
The ionomeric polymer serves multiple functions simultaneously: the metal ions provide adhesion to glass and other substrates, the polymer matrix provides structural integrity and creep resistance, and the ionomeric structure provides inherent UV and thermal stability, eliminating the need for multiple specialized additives
3Ease of manufacture
If ionomeric compositions with specific acid content are used, then adhesion to laminate layers is enhanced and lamination process is simplified, but the composition must be precisely controlled
Solution Approach 1:
The patent defines specific parameter ranges for the ionomeric composition (18-25 wt% carboxylic acid content, 0.1-5 mmol/g metal ion content) that optimize both adhesion performance and ease of manufacturing, providing clear guidance for production while ensuring consistent results
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 solution enhances adhesion to solar cell laminate layers, improves creep resistance, and simplifies the lamination process by eliminating the need for adhesion promoters, while maintaining the stability and optical clarity required for solar cell modules.
Implementation Method 1
an ionomeric composition comprising a finite amount of polymerized residues of an α-olefin and from about 18 to about 25 wt % of polymerized residues of an α,β-ethylenically unsaturated carboxylic acid
Implementation Method 2
enhances adhesion to solar cell laminate layers
Implementation Method 3
improves creep resistance
Data Source
AI summary
The present invention provides a solar cell module comprising at least one encapsulant layer which has 1) a total thickness of from about 0.1 to about 20 mils and 2) at least one surface layer made of ionomers containing a finite amount of polymerized residues of α-olefins and from about 18 to about 25 wt % of polymerized residues of α,β-ethylenically unsaturated carboxylic acids. The present invention also provides a process of manufacturing the solar cell module.