Multilayer Acid Terpolymer Encapsulant for Solar Laminates
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Solution Overview
Problem
Safety glass and solar cell encapsulant layers formed from existing acid copolymers and terpolymers lack adequate light transmission properties, adhesion strength, and heat resistance, particularly under severe environmental conditions, and require complex lamination processes.
Innovation Solution
A multilayer film or sheet comprising acid terpolymer surface sub-layers and high melting point polymer inner sub-layers, with specific compositions and thicknesses, providing enhanced adhesion, clarity, and thermal resistance, and a process for laminating solar cell pre-lamination assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acid copolymers or terpolymers are used to form safety glass interlayers or solar cell encapsulant layers, then adhesion strength and bondability are improved, but light transmission properties deteriorate
Solution Approach 1:
The patent divides the encapsulant layer into a multilayer structure with at least two distinct layers: a first layer comprising an acid copolymer or terpolymer providing adhesion strength, and a second layer comprising a different polymer providing light transmission. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The patent creates a composite material system by combining acid copolymer/terpolymer layers with other polymer layers (such as polyolefins, polyesters, or fluoropolymers) that have complementary properties. The composite structure integrates the high adhesion strength of acid polymers with the excellent optical clarity of other polymers.
2Strength
If acid copolymers or terpolymers are used to form safety glass interlayers or solar cell encapsulant layers, then adhesion strength is improved, but heat resistance deteriorates
Solution Approach 1:
The patent segments the encapsulant system into functional layers where the acid copolymer/terpolymer layer provides adhesion strength while a separate second layer with higher thermal stability provides heat resistance. This allows the low melting point acid polymers to be used without compromising overall heat resistance.
Solution Approach 2:
The patent employs composite materials combining acid copolymers/terpolymers with thermally stable polymers (such as polyolefins, polyesters, or fluoropolymers) to create an encapsulant system that achieves both strong adhesion and high heat resistance through synergistic material combination.
3Strength
If complex multicomponent compositions are used for interlayers, then adhesion and toughness are improved, but device complexity increases
Solution Approach 1:
The patent simplifies complexity by segmenting the interlayer into multiple simpler layers, each comprising a single polymer type or simple composition. This avoids the need for complex multicomponent compositions while achieving comparable or superior adhesion and toughness through the layered architecture.
Solution Approach 2:
The patent uses composite material structures where simple polymer layers are combined in specific configurations to achieve the performance of complex multicomponent compositions, thereby reducing formulation complexity while maintaining adhesion and toughness.
Data Source
AI summary
The present invention provides an acid terpolymer comprising multilayer film or sheet and safety laminates and solar cell pre-lamination assemblies comprising the same.