Olefin Copolymer Encapsulant Crosslinking for Faster Soaking
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Solution Overview
Problem
Existing crosslinking agents for ethylene/alpha-olefin copolymers in solar cell encapsulants suffer from poor miscibility, leading to prolonged soaking times and reduced productivity, while ethylene/vinyl acetate copolymers pose risks due to acetic acid gas generation.
Innovation Solution
A crosslinking agent composition for olefin-based copolymers, comprising a compound of Formula 1, such as 3-(triallylsilyl) propyl acrylate, with optional second crosslinking agents and silane coupling agents, enhances miscibility and reduces soaking time, achieving high volume resistance and light transmittance in encapsulant compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ethylene/vinyl acetate copolymer (EVA) is used as encapsulant material, then transparency, flexibility and adhesiveness are improved, but acetic acid gas is generated by decomposition which influences solar cell device
Solution Approach 1:
The patent extracts and eliminates the harmful vinyl acetate component from the copolymer structure, replacing it with alpha-olefin comonomer units that do not generate acetic acid gas upon decomposition, thereby removing the harmful factor while maintaining the desired adhesive and optical properties
Solution Approach 2:
The patent changes the chemical composition parameters of the copolymer by controlling the comonomer content (0.1-50 mol% alpha-olefin) and molecular weight (10,000-500,000), optimizing these parameters to achieve both low acetic acid generation and high adhesiveness simultaneously
2Reliability
If ethylene/alpha-olefin copolymer is used as encapsulant material, then problems of resin on hydrolysis are solved and lifetime is improved, but miscibility with polar crosslinking auxiliary agent deteriorates and soaking time increases
Solution Approach 1:
The patent changes the molecular weight parameter of the ethylene/alpha-olefin copolymer to a specific range (10,000-500,000) and controls the comonomer content (0.1-50 mol%), which optimizes the balance between hydrolysis resistance and miscibility with crosslinking agents, reducing soaking time while maintaining long lifetime
Solution Approach 2:
The patent creates a composite encapsulant system combining ethylene/alpha-olefin copolymer with specific crosslinking agents and additives, where the composite structure achieves both improved lifetime through hydrolysis resistance and reduced soaking time through optimized interfacial compatibility
3Reliability
If ethylene/alpha-olefin copolymer is used as encapsulant material, then volume resistance and insulation are improved, but miscibility with crosslinking auxiliary agent deteriorates and productivity decreases
Solution Approach 1:
The patent optimizes the molecular weight (10,000-500,000) and comonomer content (0.1-50 mol%) parameters of the copolymer to achieve the right balance between volume resistance and crosslinking agent miscibility, enabling fast soaking and high productivity without sacrificing electrical insulation properties
Solution Approach 2:
The patent develops a composite encapsulant formulation that combines ethylene/alpha-olefin copolymer with specifically selected crosslinking agents and processing aids, creating a multi-component system that simultaneously achieves high volume resistance, good miscibility, and fast processing for improved productivity
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 composition improves crosslinking efficiency, resulting in encapsulant films with enhanced volume resistance and light transmittance, suitable for various electrical and electronic applications.
Implementation Method 1
crosslinking an olefin-based copolymer and including a crosslinking auxiliary agent
Implementation Method 2
a silane coupling agent is commonly included in the solar cell encapsulant
Data Source
AI summary
Provided are a crosslinking agent composition for an olefin-based copolymer, an encapsulant composition for an optical device, an encapsulant film for an optical device, and an optoelectronic device, wherein a compound of Formula 1 is applied in the crosslinking agent composition or the encapsulant composition including an olefin-based copolymer, as a crosslinking auxiliary agent, thereby forming an encapsulant composition for an optical device and an encapsulant film for an optical device, showing excellent productivity and high volume resistance and light transmittance:wherein R1 to R4 and m are described herein.