Photovoltaic Encapsulation Material for Low-Viscosity Fiber Impregnation
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Solution Overview
Problem
Conventional encapsulation materials for photovoltaic modules face challenges in achieving flexibility, lightweight properties, and long-term stability while maintaining weathering resistance and UV stability, with acrylic resin-based materials being expensive and having poor mechanical properties, and polyester-based materials requiring high curing temperatures and displaying high viscosities that hinder impregnation.
Innovation Solution
A housing material for photovoltaic modules is developed using a powder coating material comprising an epoxy resin with an epoxy equivalent weight between 150 g/eq and 1800 g/eq and a glass transition temperature of at least 30 °C, which provides improved mechanical properties, flexibility, and chemical resistance, along with a polyester resin that can crosslink with the epoxy resin to enhance stability and reduce viscosity for better impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acrylic resin-based powder coating material is used for encapsulation, then weathering stability and UV-resistance are achieved, but the cost increases and mechanical properties deteriorate
Solution Approach 1:
The patent uses a composite material system combining polyester resin with specific additives (silane-modified polyester resin, oxirane compounds) to achieve both weathering stability and improved mechanical properties, avoiding the need for expensive acrylic resins while maintaining protective performance
2Reliability
If polyester powder coating material is used for encapsulation, then UV stability is achieved, but high curing temperatures are required increasing energy demand
Solution Approach 1:
The patent modifies the chemical parameters of the polyester resin by incorporating silane-modified polyester resin and oxirane compounds, which change the curing characteristics to allow lower curing temperatures while maintaining UV stability
3Reliability
If polyester powder coating material is used for encapsulation, then UV stability is achieved, but high viscosity hinders impregnation of fiber cloth
Solution Approach 1:
The patent changes the viscosity parameter of the polyester resin through chemical modification with silane groups and oxirane compounds, reducing the viscosity to enable proper impregnation of fiber cloth while preserving UV stability
4Reliability
If conventional encapsulation materials are used, then protection against environmental influences is achieved, but flexibility and lightweight properties cannot be realized
Solution Approach 1:
The patent creates a lightweight composite material using polyester resin combined with fiber reinforcement, achieving both environmental protection and reduced weight compared to conventional encapsulation materials
5Reliability
If conventional encapsulation materials are used, then protection against environmental influences is achieved, but coloration is difficult to achieve
Solution Approach 1:
The patent modifies the chemical structure of the polyester resin to improve its compatibility with colorants and pigments, enabling better coloration while maintaining protective performance
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 achieves a balance of mechanical strength, flexibility, and chemical resistance, while reducing the energy demand for curing and improving impregnation efficiency, thus addressing the limitations of existing materials.
Implementation Method 1
a polyester resin that can crosslink with the epoxy resin to enhance stability
Implementation Method 2
provides improved mechanical properties, flexibility, and chemical resistance, along with a polyester resin that can crosslink with the epoxy resin
Data Source
Figure 1~3
AI summary
A housing material (108) for a photovoltaic module comprises a plurality of fibers and powder coating material (104), wherein the powder coating material (104) comprises an epoxy resin with an epoxy equivalent weight in between 150 g/eq. and 1800 g/eq, wherein a glass transition temperature of the powder coating material (104) is at least 30 °C measured with Differential Scanning Calorimetry at a heating rate of 20 K / min.