Multilayer Polyolefin Encapsulant for PV Modules
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Solution Overview
Problem
Photovoltaic modules face challenges in achieving optimal mechanical, thermal, and barrier properties due to compatibility issues between different layer materials, particularly in outdoor applications where temperature and UV exposure vary widely, leading to potential degradation and adhesion problems.
Innovation Solution
A multilayer layer element comprising a first layer of ethylene copolymer with silane groups or polar comonomers and a second layer of propylene polymer, which are in direct adhering contact without additional adhesives, enhancing adhesion and providing improved mechanical, thermal, and barrier properties, as well as resistance to Potential Induced Degradation (PID).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple different layer materials are used in PV modules to achieve specific functions, then functional requirements are met, but compatibility problems arise leading to adhesion deterioration and property degradation
Solution Approach 1:
The patent employs composite materials by combining polyethylene and propylene polymers in a multilayer structure. The first layer uses polyethylene with specific density and melt flow rate properties, while the second layer uses propylene polymer, creating a composite structure that achieves both functional requirements and compatibility. This composite approach allows each layer to contribute its specific properties while maintaining overall system reliability through proven material compatibility.
2Strength
If adhesive layers are added between layer elements to improve adhesion, then bonding is enhanced, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the encapsulation and backsheet functions into a single integrated layer element consisting of two directly bonded layers. The first layer (polyethylene) and second layer (propylene) are in direct adhering contact without requiring additional adhesive layers. This merging eliminates the need for separate adhesive materials and simplifies the manufacturing process while maintaining strong adhesion through the inherent compatibility of the polyolefin materials.
3Ease of operation
If polymeric materials are used for layer elements, then flexibility and ease of processing are achieved, but thermal stability and UV resistance at high temperatures deteriorate
Solution Approach 1:
The patent carefully selects specific parameter ranges for the polymeric materials to balance processability and thermal stability. The polyethylene polymer has density of 0.910-0.960 g/cm³ and melt flow rate of 0.5-20 g/10min, while the propylene polymer has density of 0.890-0.920 g/cm³ and melt flow rate of 0.5-10 g/10min. These parameter optimizations ensure the materials remain processable at manufacturing temperatures while maintaining sufficient thermal stability for outdoor PV module applications.
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 provides a multifunctional layer element with enhanced adhesion, mechanical stability, UV resistance, and thermal stability, effectively preventing or reducing Potential Induced Degradation (PID) in photovoltaic modules, while simplifying material handling and production processes.
Implementation Method 1
a first layer (104) comprising (a) a copolymer of ethylene which bears silane group(s) containing units; or (a2) a copolymer of ethylene with one or more polar comonomer(s)... the first layer and second layer of the layer element (LE) are in adhering contact to each other
Data Source
Figure 1~2
AI summary
An article comprising a layer element (LE) of at least two layers, first layer and second layer.