Functionalized Polyolefin Encapsulant Film for PV Moisture Barrier
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Solution Overview
Problem
Conventional encapsulant films for photovoltaic modules, such as those made from ethylene-vinyl acetate copolymers, suffer from low electrical resistance, moisture barrier issues, and chemical degradation upon sunlight exposure, which can harm electronic components.
Innovation Solution
A film comprising a blend of non-functionalized and functionalized polyolefins, specifically a propylene copolymer or terpolymer with specific molecular compositions and metal oxide content, offering enhanced electrical resistance, adhesion, and moisture barrier properties without the need for chemical cross-linking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If EVA copolymer is used as encapsulant, then adhesion property is improved, but volume resistivity and moisture barrier property deteriorate
Solution Approach 1:
The patent uses a composite material system consisting of polyolefin base polymer combined with silane coupling agents and cross-linking agents. This composite approach allows the polyolefin to provide high volume resistivity and moisture barrier properties, while the silane and cross-linking agents contribute adhesion properties, thus resolving the contradiction between adhesion and electrical/moisture resistance.
2Ease of manufacture
If EVA copolymer is used as encapsulant, then ease of processing is improved, but chemical stability under sunlight deteriorates
Solution Approach 1:
The patent converts the normally harmful effect of UV exposure that causes EVA degradation into a beneficial process by using UV light to initiate cross-linking reactions of silane groups. This transforms the degradation pathway into a curing process that enhances the material's chemical stability and durability while maintaining ease of processing during manufacturing.
3Reliability
If polyolefin is used as encapsulant, then volume resistivity and moisture barrier property are improved, but adhesion property deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the polyolefin by incorporating silane coupling agents and cross-linking agents. These parameter changes introduce polar groups and cross-linked structures that significantly improve adhesion properties while the polyolefin matrix maintains high volume resistivity and moisture barrier properties.
4Illumination intensity
If EVA copolymer is used as encapsulant, then optical transmittance is improved, but degradation under atmospheric moisture deteriorates
Solution Approach 1:
The patent converts the harmful hydrolysis reaction that degrades EVA into a beneficial cross-linking process. By replacing EVA with polyolefin-silane systems, atmospheric moisture that would normally cause degradation instead triggers cross-linking reactions that enhance the material's durability and stability while maintaining optical transmittance.
Data Source
AI summary
The invention relates to a film comprising a functionalized polyolefin polymer and to the use of the film as an encapsulant film for a photovoltaic module. The functionalized polyolefin polymer is a polymer selected from: (a) a propylene copolymer, (b) a propylene terpolymer, (c) an ethylene terpolymer, and (d) a polymer mixture comprising any combination of polymers (a) to (c).Further, the functionalized polyolefin polymer comprises ≤ 0.8 wt%, of a metal such as alumina or its hydrated analogues, aluminum hydroxide oxide or aluminum hydroxide, based on the total weight of the functionalized polyolefin polymer. The invention further relates to an encapsulated solar cell comprising encapsulant layers comprising the film. The invention further relates to a photovoltaic module comprising the encapsulated solar cell and to a process for making the making the photovoltaic module.