Organic Photovoltaic Assembly Water Vapor Barrier Interlayer
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Solution Overview
Problem
Existing organic photovoltaic modules face challenges with water diffusion through thermoplastic interlayers, which degrades the functional molecules and reduces efficiency and lifetime, and not all thermoplastic interlayers are effective barriers against water vapor.
Innovation Solution
An assembly comprising a glass layer, a functional organic photovoltaic film, and a thermoplastic interlayer with a water vapor transmission rate (WVTR) less than 40 g/m²/day and a processing temperature of 120°C or lower, specifically using polyvinyl butyral (PVB) interlayers to prevent water diffusion and ensure effective lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoplastic interlayers (EVA, ionomer) are used for lamination, then good lamination performance is achieved, but water vapor transmission increases causing degradation of organic PV molecules
Solution Approach 1:
The patent changes the key parameter of water vapor transmission rate by selecting specific thermoplastic interlayer materials with WVTR < 40 g/m²/day at 85°C. This parameter change resolves the contradiction by finding materials that simultaneously achieve good lamination performance and low water vapor transmission, thereby protecting organic PV molecules from degradation while maintaining manufacturability.
2Object-affected harmful factors
If thermoplastic interlayers with high water vapor barrier properties are used, then water diffusion is blocked, but processing temperature requirements increase causing difficulty in lamination
Solution Approach 1:
The patent identifies and selects thermoplastic interlayer materials that possess both low water vapor transmission rate (WVTR < 40 g/m²/day) and low processing temperature (≤120°C). This dual parameter optimization resolves the contradiction by finding materials that provide effective water barrier protection without requiring excessive processing temperatures that would complicate manufacturing.
3Ease of manufacture
If standard lamination processes are used with conventional interlayers, then manufacturing is simple, but organic PV film stability under damp heat conditions deteriorates
Solution Approach 1:
The patent introduces a specifically selected thermoplastic interlayer as an intermediary material between the glass substrate and organic PV film. This intermediary layer acts as a protective barrier with controlled water vapor transmission properties, mediating between the external environment and the sensitive organic PV molecules. The interlayer maintains simple lamination processes while significantly improving film stability under damp heat conditions.
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 selected thermoplastic interlayers effectively block water diffusion, stabilizing the organic photovoltaic film and maintaining its efficiency and aesthetic integrity, as demonstrated by improved damp heat test results compared to other materials like EVA and ionomer films.
Implementation Method 1
a thermoplastic interlayer having a value of water vapour transmission rate (WVTR) expressed in g/m2/day less than 40
Data Source
AI summary
An organic photovoltaic assembly (1) comprising a first glass layer (2), a film comprising an organic photovoltaic component (4), at least one interlayer (3) or (5) or (7) with a water vapour transmission rate (WVTR) expressed in g/m2 day less than 40 and having a processing temperature lower or equal to 120°C and a substrate (6).