Low Modulus Solar Cell Encapsulant with Enhanced Stability
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Solution Overview
Problem
Current solar cell encapsulant layers face challenges such as low adhesion to other solar cell laminate layers, high modulus leading to reduced shock absorbance, and shortcoming in long-term stability and UV resistance, particularly with ethylene acrylate ester copolymers requiring cross-linking and adhesion primers for effective bonding.
Innovation Solution
A thermoplastic film or sheet comprising two surface layers derived from acid copolymers and/or ionomers and at least one inner layer from ethylene acrylate ester copolymers, providing enhanced adhesion, flexibility, and stability without the need for adhesion primers or cross-linking additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ethylene acrylate ester copolymers are used as encapsulant material, then flexibility and shock absorbance are improved, but adhesion to solar cell laminate layers deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of ethylene acrylate ester copolymer as the base resin combined with specific adhesion promoters and cross-linking agents. This composite approach allows the encapsulant to simultaneously achieve the flexibility and shock absorbance of the copolymer while incorporating the adhesion properties of the additives, resolving the contradiction between mechanical performance and bonding strength.
2Reliability
If adhesion primers and cross-linking additives are added to improve adhesion and stability, then adhesion and long-term stability are improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple functional components (adhesion promoters, cross-linking agents, and stabilizers) into a single integrated encapsulant formulation. By combining these previously separate additives into one unified material system, the patent simplifies the manufacturing process while maintaining improved adhesion and long-term stability, thus resolving the contradiction between performance enhancement and process simplicity.
3Stability of the object's composition
If higher modulus ionomers are used to improve structural stability, then thermal stability is improved, but shock absorbance and flexibility deteriorate
Solution Approach 1:
The patent changes the key parameter of modulus by selecting ethylene acrylate ester copolymers with lower modulus compared to traditional ionomers. This parameter change enables the material to achieve better shock absorbance and flexibility while the incorporated cross-linking agents and stabilizers maintain adequate thermal stability, thus resolving the contradiction between structural rigidity and mechanical flexibility.
Data Source
AI summary
The present invention provides a thermoplastic film or sheet comprising two surface layers made of acid copolymers, or ionomers, or combinations thereof and at least one inner layer made of ethylene acrylate ester copolymers, a solar cell module comprising at least one encapsulant layer derived therefrom, and a process of manufacturing the solar cell module.