Polymer Composite for Photovoltaic Module Encapsulation
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Solution Overview
Problem
Current photovoltaic module encapsulation materials, particularly fluoropolymer films, exhibit low adhesion to the sealing layer and limited electrical insulation, necessitating the use of thick polyester films for adequate insulation, which is inefficient.
Innovation Solution
A plastic composite comprising polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or ethylene tetrafluoroethylene copolymer (ETFE) with polyamide 12 layers is used, providing excellent adhesion to the sealing layer and sufficient electrical insulation, allowing for thinner polymer films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fluoropolymer films are used for weather resistance, then weather resistance is improved, but adhesion to sealing layer deteriorates
Solution Approach 1:
The patent employs a composite laminate structure consisting of a fluoropolymer film layer (for weather resistance) combined with a polyamide 12 layer (for adhesion). This composite material approach allows each layer to fulfill its specific function: the fluoropolymer provides external weather protection while the polyamide 12 ensures strong bonding to the sealing layer, thereby resolving the contradiction between weather resistance and adhesion.
2Object-affected harmful factors
If fluoropolymer film is used, then weather resistance is improved, but electrical insulation deteriorates
Solution Approach 1:
The laminate composite combines fluoropolymer film (providing weather resistance) with polyamide 12 (providing electrical insulation). The polyamide 12 layer compensates for the insufficient electrical insulation properties of the fluoropolymer, allowing the use of thinner overall film structures while maintaining both weather resistance and adequate electrical insulation.
Solution Approach 2:
The polyamide 12 layer serves multiple functions simultaneously: it provides electrical insulation, enhances adhesion to the sealing layer, and contributes to the overall mechanical stability of the laminate. This multi-functionality allows the system to achieve multiple performance requirements without requiring separate dedicated layers for each function.
3Reliability
If thick polyester film is used for electrical insulation, then electrical insulation is improved, but productivity deteriorates
Solution Approach 1:
The patent uses a composite laminate with polyamide 12 that provides both electrical insulation and adhesion functions. This allows the use of thinner overall film structures compared to conventional thick polyester films, reducing material consumption and simplifying the lamination process, thereby improving productivity while maintaining adequate electrical insulation.
4Reliability
If thick polymer films are used, then electrical insulation is improved, but loss of substance deteriorates
Solution Approach 1:
The laminate composite structure with polyamide 12 provides efficient electrical insulation with thinner overall film thickness. The multi-layer design optimizes material usage by assigning specific functions to each layer, reducing the total amount of polymer material required while maintaining adequate electrical insulation performance.
Data Source
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AI summary
The invention relates to the use of a polymer composite (1, 1'), comprising a backing material (3, 3'), selected from the group made up of polyethylene terephthalate (PET), polyethylene naphthenate (PEN) and ethylene-tetrafluoroethylene copolymer (ETFE), and layers of nylon 12 (2, 2', 4, 4') adjacent to the backing material on both sides, for producing photovoltaic modules.