Photovoltaic Module Adhesion Layer Using Alumina or Titanium Dioxide
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Solution Overview
Problem
Conventional photovoltaic modules with glass front faces are heavy, making them unsuitable for applications requiring lightness, and replacing glass with polymers necessitates ensuring sufficient adhesion between polymer materials and encapsulating assemblies, which is often inadequate with existing materials like EVA, ionomers, and thermoplastic polyurethanes.
Innovation Solution
Incorporating an adhesion layer of alumina (Al2O3) or titanium dioxide (TiO2) between the protective layer and the encapsulating assembly to enhance adhesion, using Atomic Layer Deposition (ALD) to apply these materials directly on the polymer surfaces, thereby improving the mechanical bonding between the protective and encapsulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass is used as the front protective layer, then mechanical strength and adhesion are improved, but weight increases
Solution Approach 1:
The patent changes the material parameter from glass to polymer (PMMA, PC, or acrylic), fundamentally altering the density and weight characteristics while maintaining protective function. This material substitution resolves the contradiction by providing sufficient mechanical strength with significantly reduced weight for portable photovoltaic applications.
Solution Approach 2:
The patent creates a composite structure by depositing an adhesion-promoting layer (silane-based or plasma-treated surface) onto the polymer protective layer. This composite approach enhances the interfacial bonding between the polymer and encapsulant, compensating for the inherently weaker adhesion of polymer materials compared to glass, thus resolving the adhesion deficiency while maintaining light weight.
2Weight of stationary object
If polymer materials are used to replace glass, then weight is reduced, but adhesion between protective layer and encapsulating assembly deteriorates
Solution Approach 1:
The patent introduces an adhesion-promoting layer as an intermediary between the polymer protective layer and the encapsulant. This intermediate layer, comprising silane-based compounds or plasma treatment, acts as a chemical mediator that enhances bonding compatibility between the polymer surface and the encapsulant material, resolving the adhesion deficiency of polymer replacements.
Solution Approach 2:
The patent modifies the surface parameters of the polymer protective layer through plasma treatment or silane deposition, changing surface energy, roughness, and chemical composition. These parameter changes improve wettability and chemical bonding capacity, thereby enhancing adhesion to the encapsulant while maintaining the lightweight polymer structure.
3Ease of manufacture
If conventional encapsulants (EVA, ionomers, thermoplastic polyurethanes) are used, then manufacturing simplicity is maintained, but adhesion to polymer protective layers is insufficient
Solution Approach 1:
The patent introduces an adhesion-promoting layer as an intermediary between the conventional encapsulant and the polymer protective layer. This intermediate layer, comprising silane-based compounds or plasma treatment, acts as a chemical mediator that enhances bonding compatibility between the polymer surface and the encapsulant material, resolving the adhesion deficiency of polymer replacements.
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
Significantly increases the adhesion force between the protective and encapsulating layers by a factor of up to 10, enabling the use of lighter polymer materials while maintaining mechanical resistance, suitable for applications with weight constraints.
Implementation Method 1
the invention relates to the adhesion produced between a protective layer of a photovoltaic module and an encapsulating assembly of the photovoltaic module
Implementation Method 2
using Atomic Layer Deposition (ALD) to apply these materials directly on the polymer surfaces
Data Source
Figure 1~3
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Figure 6~7
AI summary
The main object of the invention is a photovoltaic module (1) comprising: a protective layer (2) of the photovoltaic module (1); a plurality of photovoltaic cells (4) arranged side by side and electrically connected to each other; and an encapsulating assembly (3) for the plurality of photovoltaic cells (4). The module is characterized in that it further comprises at least one adhesion layer (8) located between the protective layer (2) and the encapsulating assembly (3), said at least one adhesion layer (8) comprising alumina (Al2O3) or titanium dioxide (TiO2). The protective layer (2) is made of at least one polymer material from the acrylate family, and the adhesion layer (8) is in direct contact with the protective layer and with the encapsulating assembly.