Lightweight Photovoltaic Laminated Structure Using Polyester Composite Encapsulation
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Solution Overview
Problem
The existing laminated structures of photovoltaic assemblies are heavy, costly, and have complex lamination processes, failing to meet anti-ultraviolet, anti-aging, anti-impact, and anti-insulation standards, which complicates installation and increases construction difficulties.
Innovation Solution
A laminated structure comprising a first and second encapsulation layer with fiber cloth and polyester or acrylic powder coatings, applied in a three-stage lamination process at controlled temperatures, ensuring uniformity and reducing weight and energy consumption, while meeting technical standards for photovoltaic industry requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional encapsulation materials (toughened glass, high-transparent film, transparent backplane) are used, then the photovoltaic assembly meets anti-impact and fire protection standards, but the weight is excessive and installation convenience is reduced
Solution Approach 1:
The patent uses composite encapsulation materials consisting of polyester resin combined with fiber reinforcement (glass fiber, basalt fiber, or carbon fiber) to achieve both lightweight properties and high mechanical strength. This composite structure provides anti-impact performance comparable to or exceeding conventional toughened glass while significantly reducing weight.
Solution Approach 2:
The patent modifies the chemical composition and physical parameters of the encapsulation material by using polyester resin with specific molecular weight, hydroxyl value, and viscosity ranges, combined with fiber reinforcement, to achieve optimal balance between weight reduction and mechanical strength enhancement.
2Reliability
If fluoropolymer materials are used for encapsulation, then anti-corrosion and weather resistance are improved, but the production cost increases significantly
Solution Approach 1:
The patent replaces expensive fluoropolymer materials with more economical polyester resin combined with fiber reinforcement, achieving comparable or superior weather resistance and mechanical properties at a fraction of the cost. The polyester-based composite provides cost-effective encapsulation without sacrificing reliability.
Solution Approach 2:
The combination of polyester resin with fiber reinforcement creates a composite material that delivers weather resistance, mechanical strength, and cost-effectiveness, eliminating the need for expensive fluoropolymer alternatives.
3Weight of moving object
If acrylate containing epoxy group is used as encapsulation material, then lightweight performance is achieved, but the lamination temperature and energy consumption increase, and the laminated structure becomes curved and uneven
Solution Approach 1:
The patent optimizes the viscosity and molecular weight parameters of the polyester resin to achieve proper flow and curing characteristics at reduced lamination temperatures (100-180°C), significantly lowering energy consumption compared to acrylate-based systems that require higher temperatures.
Solution Approach 2:
The patent replaces the chemical curing mechanism of acrylate epoxy systems with polyester resin curing through reaction with organometallic catalysts, enabling lower temperature processing and better control of lamination flatness.
4Reliability
If liquid coating process is used for backplane coating, then weather resistance is improved, but the process complexity increases, defect rate increases, and equipment investment increases
Solution Approach 1:
The patent replaces complex liquid coating processes with a simplified lamination process where polyester resin-impregnated fiber cloth is layered and cured, eliminating the need for liquid coating equipment, solvent handling systems, and complex process control while achieving comparable or superior weather resistance.
Solution Approach 2:
The patent transitions from liquid coating to a dry lamination process using polyester resin with controlled viscosity and curing characteristics, simplifying the manufacturing process and reducing equipment requirements while maintaining protective performance.
5Stability of the object's composition
If conventional encapsulation materials are used, then structural stability is maintained, but the lamination process becomes complex and installation difficulty increases
Solution Approach 1:
The patent modifies the viscosity and curing characteristics of the polyester resin to enable lamination at lower temperatures with better flow properties, resulting in easier handling, simpler installation processes, and reduced labor requirements while maintaining structural stability.
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 results in a lightweight, cost-effective photovoltaic assembly with improved installation convenience and reduced labor intensity, meeting anti-ultraviolet, anti-aging, anti-impact, and anti-insulation standards, and enabling aesthetic installation on various building structures.
Implementation Method 1
the polyester obtained by crosslinking and curing the resins as the encapsulation material
Implementation Method 2
the polyester obtained by crosslinking and curing the resins as the encapsulation material
Implementation Method 3
a typical laminated structure of photovoltaic assemblies (commonly called laminates) is formed by successively laminating
Implementation Method 4
Solar photovoltaic power generation relies on solar cells to convert light energy directly into electricity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A laminated structure of a photovoltaic assembly. The laminated structure comprises a first packaging layer (11a), a solar cell array (13a), and a second packaging layer (14a). The first packaging layer (11a) is prepared by using 30 to 50 parts of fiber cloth and 50 to 70 parts of first packaging powder coating in parts by weight, and the first packaging powder coating is evenly coated on the fiber cloth. The second packaging layer (14a) is prepared by using 30 to 50 parts of fiber cloth and 50 to 70 parts of second packaging powder coating in parts by weight, and the second packaging powder coating is evenly coated on the fiber cloth. The first packaging powder coating is an acrylic acid powder coating or a super-weather-resistant polyacrylic acid powder coating, and the second packaging powder coating is a super-weather-resistant polyester powder coating. The laminated structure has low costs, and the light weight of the packaging materials of the photovoltaic assembly is achieved on the premise that ultraviolet resistance, aging resistance, impact resistance, fire resistance and other technical requirements in the photovoltaic industry.