PV Module Packaging Material With Composite Coating for Lightweight Durability
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Solution Overview
Problem
Existing photovoltaic module encapsulant materials are heavy, making installation difficult and costly, and fail to meet industry standards for UV resistance, anti-aging, impact resistance, and fire prevention.
Innovation Solution
A lightweight encapsulant material composed of 30-50 parts by weight of fiber cloth and 50-70 parts by weight of weather-resistant polyester powder coating, evenly distributed and thermally bonded, which replaces conventional tempered glass, providing UV resistance, anti-aging, impact resistance, and fire prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tempered glass is used as encapsulant material, then UV resistance and impact resistance are improved, but weight increases significantly
Solution Approach 1:
The patent uses a composite structure consisting of a polyester nonwoven fabric base layer combined with a weather-resistant polyester powder coating layer. This composite material achieves both light weight and high performance, providing UV resistance, impact resistance, and fire prevention properties while significantly reducing weight compared to tempered glass.
2Weight of stationary object
If highly transparent films such as EVA or POE are used to replace tempered glass, then weight is reduced, but impact resistance and fire resistance deteriorate
Solution Approach 1:
The patent employs a composite material system where a polyester nonwoven fabric provides structural integrity and fire resistance, while the weather-resistant polyester powder coating provides UV resistance and enhanced mechanical strength. This composite structure achieves both weight reduction and maintained reliability.
Solution Approach 2:
The patent changes the material parameters by using polyester-based materials with specific technical indicators: tensile strength ≥25 MPa, elongation at break ≥150%, and acid value within specific ranges. These parameter optimizations ensure the material meets industry standards for impact resistance and fire resistance while maintaining light weight.
3Reliability
If fluorine-containing polymers are used for weather-resistant coating, then UV resistance and anti-aging properties are improved, but production cost increases
Solution Approach 1:
The patent replaces expensive fluorine-containing polymers with a more economical weather-resistant polyester powder coating that contains UV absorbers and hindered amine light stabilizers. This substitution significantly reduces production costs while maintaining effective UV resistance and anti-aging properties through the polyester resin matrix.
Solution Approach 2:
The patent optimizes the chemical composition parameters of the polyester powder coating, specifying that it contains UV absorbers and hindered amine light stabilizers in appropriate concentrations. This parameter optimization provides cost-effective UV protection and anti-aging performance without requiring expensive fluorine-containing polymers.
4Ease of manufacture
If liquid coating processes are used for weatherproof coating, then coating application is simplified, but production time increases and defective rate increases
Solution Approach 1:
The patent uses powder coating material that transitions from solid powder to melted coating layer through thermal curing at 130-150°C for 5-15 minutes. This phase transition approach eliminates the need for liquid solvents and lengthy drying processes, significantly reducing production time and defective rate while maintaining ease of application.
Solution Approach 2:
The patent replaces the liquid coating process with a powder coating process that uses thermal energy instead of chemical solvents. The powder coating is applied and then cured through heating, which melts and fuses the powder particles to form a continuous protective film. This substitution eliminates solvent evaporation time and reduces production defects.
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 encapsulant material significantly reduces the weight of photovoltaic modules, simplifies installation, reduces labor intensity, and lowers installation costs while meeting industry standards for UV resistance, anti-aging, and fire prevention.
Implementation Method 1
wherein the polyester resin and the curing agent are evenly distributed on the fiber cloth
Data Source
Figure 1
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Figure 3~5
AI summary
Disclosed is a packaging material for a photovoltaic module, comprising the following raw materials in parts by weight: 30-50 parts of fiber fabric woven by a fiber material; and 50-70 parts of super-weather-resistance polyester powder coating comprising a super-weather-resistance polyester resin and a curing agent. The fiber fabric is uniformly coated with super-weather-resistance polyester powder coating. The present invention is low in manufacturing cost. Moreover, while meeting the prerequisites of resistance to ultraviolet, aging, impact, and fire which are technical standard requirements of the photovoltaic industry, the present invention efficiently realizes lightweight of the packaging material for a photovoltaic module, makes installation more convenient, reduces the installation cost, and thus is very suitable for large-scale promotion and application in the photovoltaic field. Also disclosed is a method for preparing the packaging material for the photovoltaic module. The method meets the installation requirements for changing the packaging size of a photovoltaic module at will to adapt to different buildings and thus further facilitates installation and application of photovoltaic modules.