Polyethylene-Layer Insulation Film for Thin Steel-Backed Solar Modules

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Solution Overview

Problem

Existing solar cell modules face issues with insufficient insulation and adhesion between the solar cell and steel sheet, leading to potential short circuits and increased complexity and cost in production, particularly in steel sheet integrated modules with back contact type solar cells.

Innovation Solution

A solar cell module insulation film comprising a sealing material layer, an insulating substrate, and a polyethylene-based resin layer with a wetting tension of 36 dyne/cm or more, which improves adhesion to the steel sheet and reduces thickness, allowing for simplified production processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick sealing material sheet is used between the solar cell and steel sheet, then insulation performance is improved, but the overall thickness of the solar cell module increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidmodule thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent uses a composite structure consisting of a sealing material sheet and a polyethylene-based resin layer. The sealing material sheet provides insulation performance, while the polyethylene-based resin layer with high wetting tension (36 dyne/cm or more) provides adhesion to the steel sheet. This composite approach allows achieving both good insulation and strong adhesion without requiring excessive thickness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the wetting tension parameter of the polyethylene-based resin layer to 36 dyne/cm or more. By controlling this physical parameter, the adhesion performance to the steel sheet is significantly improved, allowing the use of thinner materials while maintaining reliable bonding.

Inventive Principle:

Principle #35Parameter changes

2Length of stationary object

If a thin sealing material sheet is used between the solar cell and steel sheet, then module thickness is reduced, but adhesion performance becomes insufficient

Engineering Contradiction:

Improvemodule thicknessVSAvoidadhesion performance

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The patent changes the wetting tension parameter of the polyethylene-based resin layer to 36 dyne/cm or more. This parameter change fundamentally improves the adhesion mechanism, allowing thin materials to achieve strong bonding with the steel sheet through enhanced surface interaction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The composite structure combines a thin sealing material sheet with a polyethylene-based resin layer that has specialized adhesion properties. The resin layer acts as an effective bonding agent, compensating for the reduced thickness of the sealing material sheet and maintaining reliable adhesion.

Inventive Principle:

Principle #40Composite materials

3Reliability

If multiple separate materials are layered and integrated by thermal compression, then insulation and adhesion are achieved, but production complexity and cost increase

Engineering Contradiction:

Improveinsulation and adhesionVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the sealing material sheet and the polyethylene-based resin layer into a single integrated component. This consolidation eliminates the need for separate thermal compression processing and multiple material layers, significantly simplifying the production process while maintaining the required insulation and adhesion performances.

Inventive Principle:

Principle #5Merging (Combining)

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 insulation film enhances adhesion and insulation, reduces module thickness, and simplifies production by eliminating the need for silane coupling agents, thereby improving productivity and reducing costs.

Implementation Method 1

a wetting tension of a surface of the polyethylene-based resin layer that is opposite side to the insulating substrate is 36 dyne/cm or more

Methodology Applied

Scientific EffectWetting tension: Surface Tension

Data Source

PatentUS20250324774A1Solar cell module insulation film, insulation film with steel sheet, insulation film with wiring sheet, and solar cell module

Publication Date: 2025.10.16 DAI NIPPON PRINTING CO LTD

AI summary

A solar cell module insulation film disposed between a solar cell and a steel sheet in a solar cell module, the solar cell module insulation film including: a sealing material layer, an insulating substrate, and a polyethylene-based resin layer, in this order, wherein the polyethylene-based resin layer is a polyethylene film; and a wetting tension of a surface of the polyethylene-based resin layer that is opposite side to the insulating substrate is 36 dyne/cm or more.