NMR Polymer Analysis for Non-Destructive Lamination Quality Control
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Solution Overview
Problem
Current methods for assessing the lamination quality of photovoltaic modules and safety glasses are destructive, time-consuming, and inadequate for glass-glass modules, and existing non-destructive methods lack comprehensive analysis capabilities, particularly for various encapsulation films and thermal gradients.
Innovation Solution
A non-destructive nuclear magnetic resonance (NMR) spectroscopy method involving radiofrequency pulse sequences is used to analyze polymer samples, determining microstructure-dependent parameters such as cross-linking degree, crystallinity, and water content, applicable to both monolayer and multilayer samples, including glass-glass modules and safety glasses, by measuring spin-lattice and spin-spin relaxation times and dipole-dipole couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive methods like Soxhlet extraction are used to test lamination quality, then measurement precision is improved, but productivity deteriorates due to time consumption and sample destruction
Solution Approach 1:
The patent replaces destructive mechanical/chemical extraction methods (Soxhlet extraction) with non-destructive magnetic resonance imaging to assess lamination quality. This substitution eliminates sample destruction and reduces testing time from 24 hours to a fraction of that time, while maintaining measurement precision through direct imaging of the polymer matrix and encapsulant interface.
Solution Approach 2:
The patent creates a non-destructive copy or representation of the lamination quality through magnetic resonance imaging signals. Instead of physically extracting and analyzing components, the method generates imaging data that replicates the information about lamination quality, crosslinking degree, and encapsulant integrity without consuming the sample.
2Productivity
If existing non-destructive methods like Raman spectroscopy are used, then productivity is improved, but measurement precision deteriorates due to limited analysis capabilities
Solution Approach 1:
The patent enhances measurement precision by making the magnetic resonance imaging method universally applicable to multiple encapsulant types (EVA, POE, ionomers, polyurethanes) and various lamination qualities. Unlike Raman spectroscopy that works well only for specific materials, this method provides comprehensive analysis across different polymer compositions and lamination states through adjustable imaging parameters.
Solution Approach 2:
The patent improves measurement precision by enabling adjustment of multiple imaging parameters including magnetic field strength, radiofrequency pulse sequences, and temperature control. These parameter changes allow optimization of the imaging process for different encapsulant types and lamination conditions, providing detailed quantitative information about crosslinking degree and encapsulant integrity that exceeds the capabilities of fixed-parameter methods.
3Ease of operation
If non-destructive methods are used for single-sided analysis, then ease of operation is improved, but measurement precision deteriorates due to incomplete lamination control
Solution Approach 1:
The patent transitions from single-sided surface analysis to three-dimensional volumetric imaging of the entire photovoltaic module. The magnetic resonance imaging method penetrates through the module structure to provide cross-sectional and volumetric views of lamination quality, enabling assessment of both front and back lamination interfaces simultaneously without additional operational complexity.
4Measurement precision
If destructive methods are used to analyze glass-glass modules, then measurement precision is improved, but ease of operation deteriorates due to complicated sample extraction
Solution Approach 1:
The patent replaces complicated mechanical sample extraction and disassembly procedures with non-destructive magnetic resonance imaging. The imaging method penetrates through the glass substrates and encapsulants to directly visualize lamination quality without requiring physical access to internal interfaces, eliminating the operational complexity of sample preparation for glass-glass modules.
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
Enables fast, efficient, and comprehensive in-situ lamination quality control and degradation assessment of polymer samples, allowing for both inline and offline analysis with high sensitivity and resolution, identifying critical parameters affecting module lifetime without destruction.
Implementation Method 1
subjecting the polymer sample to a magnetic field of a magnet; applying a radiofrequency pulse sequence to the polymer sample; obtaining a radiofrequency signal response from the polymer sample
Data Source
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AI summary
The invention relates to a method for analysing a polymer sample (2) with nuclear magnetic resonance (NMR), the method comprising the following steps: providing a polymer sample (2); tempering a polymer sample (2); measuring a surface temperature of the polymer sample (2); subjecting the polymer sample (2) to a magnetic field of a magnet (4); applying a radiofrequency pulse sequence to the polymer sample (2); obtaining a radiofrequency signal response from the polymer sample (2); determining a microstructure-dependent parameter of the polymer sample (2) on the basis of the signal response.