Polymer Composition for Photovoltaic Module Layers
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Solution Overview
Problem
Current polymer compositions for photovoltaic module layers face challenges in achieving optimal viscosity for efficient film extrusion and adhesion while maintaining storage stability, and they often require crosslinking processes that are difficult to control.
Innovation Solution
A polymer composition comprising ethylene with a polar comonomer, such as methyl acrylate, and silane groups, which provides high Melt Flow Rate (MFR) and Shear Thinning Index, enabling improved rheological and adhesion properties without the need for additional crosslinking steps, thereby enhancing production rates and storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crosslinkable silane groups are incorporated into the polymer to improve adhesion and viscosity properties, then adhesion and viscosity are improved, but storage stability is impaired due to uncontrolled crosslinking reactions during storage
Solution Approach 1:
The patent changes the chemical parameters of the polymer by incorporating specific polar comonomers (methyl acrylate or methyl methacrylate) and silane groups in controlled amounts. This modifies the polymer's rheological properties and adhesion characteristics without triggering uncontrolled crosslinking during storage, thus improving adhesion while maintaining storage stability.
Solution Approach 2:
The patent creates a composite polymer system by combining ethylene base polymer with polar comonomer units and silane groups. This composite structure achieves both improved adhesion properties and controlled rheology without the harmful effects of premature crosslinking, resolving the contradiction between strength improvement and stability maintenance.
2Strength
If conventional crosslinking processes are used to improve adhesion properties, then adhesion is improved, but device complexity increases due to additional processing steps and catalyst requirements
Solution Approach 1:
The patent extracts the crosslinking function from the processing stage and integrates it into the polymer composition itself through the inclusion of silane groups. This eliminates the need for separate crosslinking processes, catalysts, and additional processing steps, thereby reducing device complexity while maintaining improved adhesion properties.
Solution Approach 2:
The polymer composition is designed to be self-sufficient by incorporating silane groups that provide the necessary crosslinking capability within the base polymer itself. This self-service approach eliminates dependency on external catalysts and additional processing equipment, simplifying the overall manufacturing process while achieving the desired adhesion improvement.
3Productivity
If polymer composition is optimized for efficient film extrusion with low processing viscosity, then productivity is improved, but adhesion properties deteriorate due to insufficient zero shear rate viscosity
Solution Approach 1:
The patent optimizes the rheological parameters of the polymer by carefully selecting the types and amounts of polar comonomers and silane groups. This creates a polymer composition with optimized viscosity characteristics that enables efficient film extrusion at processing conditions while maintaining sufficient zero shear rate viscosity for good adhesion properties, thus resolving the contradiction between productivity and adhesion.
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 polymer composition offers a balanced property profile with excellent adhesion, optical, and mechanical properties, along with improved heat stability and electrical resistivity, making it suitable for photovoltaic module applications without the need for conventional crosslinking agents.
Implementation Method 1
a Shear Thinning Index, SHI0.05/300, of 10.0 to 35.0, when measured according to 'Rheological properties: Dynamic Shear Measurements (frequency sweep measurements)'
Data Source
AI summary
The present invention relates to a polymer composition, to a layer element, preferably to at least one layer element of a photovoltaic module, comprising the polymer composition and to an article which is preferably said at least one layer of a layer element, preferably of a layer element of a photovoltaic module.