PV Module Backsheet Adhesion via Oxazoline Primer
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Solution Overview
Problem
Current backsheet materials for photovoltaic modules, particularly those using fluorine-based polymers, face challenges with adhesion to substrates like PET, requiring high-temperature processing, expensive equipment, and leading to increased production costs and potential thermal deformation of substrates.
Innovation Solution
A multi-layered film comprising a substrate with a primer layer containing an oxazoline group-containing polymer and a resin layer made of a fluorine-based polymer, which improves adhesive strength and allows for low-temperature drying, reducing manufacturing costs and enhancing durability and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fluorine-based polymer film is laminated on a substrate using a urethane-based adhesive, then adhesion is improved, but manufacturing complexity and cost increase due to additional equipment, adhesive coating, and laminating processes
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary substance between the substrate and fluorine-based polymer film. The silane coupling agent contains both inorganic (silane) and organic (functional groups) components, enabling it to bond with both the substrate and the fluorine-based polymer, thereby achieving strong adhesion without requiring complex lamination equipment or additional adhesive coating processes
Solution Approach 2:
The patent changes the chemical parameters of the substrate surface by treating it with a silane coupling agent solution. This treatment modifies the surface chemistry of the substrate, creating reactive sites that can form strong bonds with the fluorine-based polymer film, thereby improving adhesion through chemical parameter modification rather than mechanical lamination
2Reliability
If a fluorine-based polymer resin solution is coated and dried on a substrate, then film formation is achieved, but high drying temperature of 200°C or higher is required, increasing production costs and causing thermal shocks or deformation
Solution Approach 1:
The patent changes the solvent parameters by using a low-boiling-point solvent instead of traditional high-boiling-point solvents. This parameter change allows the resin solution to be dried at temperatures of 100°C or lower, avoiding thermal shocks and substrate deformation while still achieving proper film formation. The low-boiling-point solvent evaporates more readily, enabling low-temperature processing
Solution Approach 2:
The patent employs a low-boiling-point solvent that can be easily evaporated and discarded after serving its purpose of dissolving the fluorine-based polymer. This disposable solvent approach eliminates the need for high-temperature drying equipment and reduces energy consumption, as the solvent naturally evaporates at low temperatures without requiring sustained high-heat treatment
3Manufacturing precision
If high-temperature heat is applied to a PVF resin solution, then drying and film formation are achieved, but production costs increase and mechanical properties deteriorate over long-term outdoor use
Solution Approach 1:
The patent changes the drying temperature parameter from high (200°C or higher) to low (100°C or lower) by using a low-boiling-point solvent. This parameter change reduces energy consumption and eliminates the need for expensive high-temperature drying equipment, thereby reducing production costs while still achieving proper film formation through the solvent's natural evaporation characteristics
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 backsheet with enhanced adhesive strength, durability, and weather resistance, enabling photovoltaic modules to withstand long-term outdoor exposure while minimizing production costs and thermal issues.
Implementation Method 1
a primer layer including an oxazoline group-containing polymer which is formed on the substrate, and a resin layer including a fluorine-based polymer which is formed on the primer layer
Implementation Method 2
a solvent having a low boiling point, and a fluorine-based polymer in which a melting point is 155° C. or lower or a softening point is 100° C. or lower
Data Source
AI summary
A multi-layered film, a backsheet for photovoltaic modules, a method of manufacturing the same, and a photovoltaic module are provided. The multi-layered film having excellent reliability and adhesive strength under high heat/moisture conditions and also showing excellent weather resistance and durability may be provided by forming a primer layer including an oxazoline group-containing polymer on a substrate and forming a resin layer including a fluorine-based polymer on the primer layer. The primer layer and resin layer of the multi-layered film may be manufactured at a low cost under a low drying temperature using a solvent having a low boiling point, so that the manufacturing costs can be reduced and the quality of the product can be prevented from being deteriorated by thermal deformation or thermal shock. The multi-layered film may be effectively used for a backsheet for photovoltaic modules so that the photovoltaic module can exhibit excellent durability even when exposed to external environments for a long time.