Patterned Adhesive Film Lamination Without PV Module Cracking
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Solution Overview
Problem
Conventional patterned adhesive films used in photovoltaic assemblies tend to crack during the laminating process due to their poor tensile properties, which leads to packaging losses and inefficiencies.
Innovation Solution
A patterned adhesive film comprising a bottom-layer adhesive film with a minimum torque value of 0.2-2.5 dN·m at 100° C and a patterned coating layer with an elongation at break of ≥20%, formed from ethylene-vinyl acetate copolymer or octene-polyolefin, and a UV resin-based coating composition, ensuring low fluidity and strong adhesion to prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a patterned coating layer is applied on the adhesive film to solve packaging loss, then packaging efficiency is improved, but the tensile property deteriorates causing cracks during lamination
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive film by controlling the minimum torque value ML at 100°C to be within 0.2-2.5 dN·m and the pre-crosslinking degree to be within 5-60%. These parameter adjustments optimize the balance between adhesion and tensile strength, preventing cracks while maintaining packaging efficiency.
Solution Approach 2:
The patent uses composite materials consisting of ethylene-vinyl acetate copolymer and/or octene-polyolefin as the adhesive film base, combined with a patterned coating layer. This composite structure integrates the advantages of both materials: the adhesive film provides flexibility and adhesion, while the patterned coating layer provides packaging efficiency, resolving the contradiction between tensile strength and packaging performance.
2Area of stationary object
If the adhesive film has high fluidity to fill gaps during lamination, then packaging coverage is improved, but the patterned coating layer cracks due to excessive flow
Solution Approach 1:
The patent precisely controls the minimum torque value ML at 100°C within 0.2-2.5 dN·m to regulate the fluidity of the adhesive film. This parameter optimization ensures the adhesive film has sufficient fluidity to fill gaps and achieve complete packaging coverage, while preventing excessive flow that would cause the patterned coating layer to crack.
3Force
If the pre-crosslinking degree is increased to improve adhesion strength, then bonding force is improved, but the elongation at break decreases reducing flexibility
Solution Approach 1:
The patent optimizes the pre-crosslinking degree parameter within 5-60% to achieve the best balance between adhesive force and elongation at break. This parameter control ensures sufficient bonding strength between the adhesive film and patterned coating layer while maintaining the flexibility and crack resistance needed during the lamination process.
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 solution effectively prevents cracking of the patterned adhesive film during lamination, maintaining the structural integrity and efficiency of photovoltaic assemblies by matching the fluidity and elongation of the bottom-layer adhesive film with the patterned coating layer, thereby enhancing power generation performance.
Implementation Method 1
the minimum torque value ML of the bottom-layer adhesive film at 100° C. is 0.2-2.5 dN·m
Implementation Method 2
the elongation at break of the patterned coating layer is ≥20%
Implementation Method 3
a patterned adhesive film includes a bottom-layer adhesive film and a patterned coating layer arranged on the surface of the bottom-layer adhesive film
Data Source
AI summary
Provided are a patterned adhesive film and a photovoltaic assembly. The patterned adhesive film includes a bottom-layer adhesive film and a patterned coating layer arranged on the surface of the bottom-layer adhesive film, the minimum torque value ML of the bottom-layer adhesive film at 100° C. is 0.2-2.5 dN·m, and the elongation at break of the patterned coating layer is ≥20%. Therefore, while laminating is performed on the photovoltaic assembly including the patterned adhesive film, the bottom-layer adhesive film has relatively low fluidity, and the elongation at break of the patterned coating layer may be matched with the bottom-layer adhesive film having the relatively low fluidity, such that the cracking problem of the patterned adhesive film is avoided in the laminating process of the photovoltaic assembly.