Polyamide-Grafted Polyolefin Encapsulant for PV Modules
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Solution Overview
Problem
Conventional thermoplastic materials used in photovoltaic modules, such as EVA and polyolefin-based encapsulants, face durability issues due to acetic acid release in humid heat and sensitivity to potential-induced degradation (PID), and polyamide-grafted polyolefins exhibit high humidity absorption, limiting module lifespan.
Innovation Solution
A thermoplastic composition comprising a polyamide-grafted polyolefin with specific polyamide grafts and copolymers, including ethylene and alkyl (meth)acrylate copolymers, that provides improved mechanical, optical, and electrical properties while minimizing water absorption and degradation over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyamide-grafted polyolefin is used to improve mechanical properties and adhesion, then bonding strength is improved, but water absorption increases significantly
Solution Approach 1:
The patent changes the chemical composition parameters by specifying polyamide graft content between 10-60% and controlling the ratio of polyamide-grafted polyolefin to polyolefin resin. This parameter optimization achieves the balance between bonding strength (improved by polyamide grafts) and water absorption (reduced by limiting polyamide content and adding hydrophobic polyolefin), resolving the technical contradiction.
2Strength
If conventional thermoplastic materials like EVA are used to ensure good bonding, then adhesion is improved, but durability deteriorates due to acetic acid release and PID sensitivity
Solution Approach 1:
The patent extracts and eliminates the harmful components (acetic acid release and PID sensitivity) by replacing EVA with a polyolefin-based composition. The polyolefin resin and polyamide-grafted polyolefin combination provides good adhesion without the degradation issues of EVA, thus improving durability while maintaining bonding strength.
3Reliability
If polyolefin-based encapsulants are used to improve durability and resistance to degradation, then reliability is improved, but creep resistance deteriorates
Solution Approach 1:
The patent creates a composite material system combining polyolefin resin (providing creep resistance and structural stability) with polyamide-grafted polyolefin (providing adhesion and durability). This composite approach allows the material to simultaneously achieve good creep resistance from the polyolefin matrix and improved durability from the polyamide-grafted component, resolving the contradiction between reliability and strength.
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 ensures low water resistance and enhanced long-term durability, maintaining photoelectric properties and structural integrity under extreme conditions, effectively addressing the limitations of previous materials.
Implementation Method 1
the polyamide grafts are attached to the polyolefin trunk by the remainder of the unsaturated monomer (X) comprising a function capable of reacting by a condensation reaction with a polyamide
Data Source
AI summary
The invention relates to a thermoplastic composition comprising a mixture of three particular and different polyolefins, including one consisting of a polyamide-grafted polyolefin having particular polyamide grafts (type and quantity). The invention also relates to a thermoplastic film and, more specifically, a film for encapsulating a photovoltaic module incorporating the polyamide-grafted polyolefin composition.