Multi-layered PVF Backsheet Adhesion via Polymer Coating
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Solution Overview
Problem
Current photovoltaic module backsheets using fluorine-based polymers face challenges with poor adhesion to PET substrates, requiring high-temperature processing, expensive equipment, and limited use of additives, leading to increased production costs and degradation of mechanical properties over time.
Innovation Solution
A multi-layered sheet with a polymer coating layer compatible with fluorine-based resins, featuring a fluorine-based resin layer with low crystallinity and a solvent with a boiling point of 200°C or less, enhancing adhesion and allowing low-temperature drying, thereby reducing production costs and improving durability and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVF resin is used with a substrate, then weather resistance and durability are improved, but adhesion to PET film is poor requiring additional adhesive layers and processes
Solution Approach 1:
The patent introduces a polymer coating layer as an intermediary between the PVF resin layer and the PET substrate. This intermediate layer is specifically designed to be compatible with both the fluorine-based resin and the substrate, enabling strong adhesion without requiring additional adhesive layers or complex lamination processes.
2Ease of manufacture
If fluorine-based polymer film is coated and dried on substrate, then resin application is achieved, but high drying temperature of 200°C or more is needed consuming large energy
Solution Approach 1:
The patent modifies the chemical composition parameters of the polymer coating layer to enable low-temperature drying. By selecting specific polymers with appropriate glass transition temperatures and compatibility characteristics, the drying temperature is reduced from 200°C or higher to below 200°C, significantly reducing energy consumption while maintaining coating quality.
3Ease of manufacture
If high drying temperature is used, then resin drying is achieved, but thermal shock or thermal deformation of substrate occurs degrading product quality
Solution Approach 1:
The patent changes the drying temperature parameter from high (200°C or more) to low (below 200°C) by modifying the polymer coating composition. This parameter change prevents thermal shock and thermal deformation of the PET substrate, maintaining the mechanical properties and quality of the final photovoltaic module backsheet.
4Reliability
If conventional fluorine-based polymer film is used, then weather resistance is achieved, but production cost increases due to expensive equipment and additional processes
Solution Approach 1:
The patent combines the adhesive function and the polymer coating function into a single integrated layer. The polymer coating layer simultaneously provides adhesion between the PVF resin and substrate while serving as the drying medium, eliminating the need for separate adhesive layers and high-temperature drying processes, thereby reducing production costs.
5Ease of operation
If thicker film is used to handle the film, then handling is improved, but adhesion and mechanical properties deteriorate
Solution Approach 1:
The patent changes the thickness parameter of the PVF resin layer by improving the adhesion mechanism through the polymer coating layer. This allows the use of thinner PVF layers (reducing material cost and improving performance) while maintaining strong adhesion and mechanical properties, as the polymer coating provides the necessary bonding strength.
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 strong adhesion and durability to the substrate, preventing thermal deformation and enhancing the quality and productivity of photovoltaic modules, while maintaining excellent weather resistance and mechanical properties.
Implementation Method 1
a polymer coating layer that is compatible with a fluorine-based resin between the substrate and the fluorine-based resin layer
Implementation Method 2
coating a coating solution including a fluorine-based resin having an amorphous region and a crystallinity of less than 60% and a solvent having a boiling point of 200° C. or less on the polymer coating layer
Data Source
AI summary
Provided are a multi-layered sheet, a backsheet for a photovoltaic cell, a method of preparing the same and a photovoltaic module. The multi-layered sheet in which a resin layer including a fluorine-based resin has excellent durability and weather resistance, and also exhibits strong interfacial adhesion to a substrate or polymer coating layer is provided. When a drying process is performed at a low temperature in preparation of the multi-layered sheet, production cost can be reduced, producibility can be increased, and degradation in the quality of a product caused by thermal deformation or thermal shock can be prevented. Such a multi-layered sheet may be effectively used as a backsheet for various photovoltaic cells.