Silane-Grafted Polymer Composition for UV-Resistant PV Modules

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Solution Overview

Problem

Photovoltaic (PV) modules face degradation due to UV radiation exposure, which shortens their lifespan and affects performance, and conventional UV-absorbing agents can cause unwanted coloring and are costly.

Innovation Solution

A polymer composition comprising ethylene-based polymers with silane groups and a low amount of pigment, which effectively blocks UV radiation and reflects photons, used as a rear encapsulation layer in PV modules, eliminating the need for peroxide crosslinking and reducing UV impact on adjacent layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional UV-absorbing agents are used to protect PV modules from UV radiation, then UV protection is improved, but unwanted coloring effects occur and costs increase

Engineering Contradiction:

ImproveUV radiation protectionVSAvoidunwanted coloring effects

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the polymer by incorporating specific comonomers with UV-absorbing functional groups (such as benzophenone, benzotriazole, or triazine groups) directly into the polymer chain. This eliminates the need for separate UV-absorbing agents and prevents unwanted coloring effects while maintaining effective UV protection.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite polymer material by combining ethylene or alpha-olefin base polymer with comonomers containing UV-absorbing functional groups. This composite structure integrates UV protection functionality directly into the polymer matrix, avoiding the need for additional UV-absorbing agent additives that cause coloring issues.

Inventive Principle:

Principle #40Composite materials

2Reliability

If UV-absorbing agents are added to protect polymeric back layer elements, then UV deterioration is reduced, but the agents have limited lifetime and are costly

Engineering Contradiction:

ImproveUV resistance of back layerVSAvoidlifetime of UV-absorbing agents

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent incorporates UV-absorbing functional groups directly into the polymer chain during the polymerization process, before the PV module is assembled and exposed to UV radiation. This preliminary incorporation ensures the UV protection is intrinsic to the material and will last throughout the entire lifetime of the PV module, eliminating the limited lifetime issue of additive-based UV absorbers.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The polymer itself provides UV protection through its own molecular structure containing UV-absorbing comonomers. This self-service approach eliminates the need for separate UV-absorbing agents that deplete over time, providing long-term, sustainable UV protection without additional cost or lifetime limitations.

Inventive Principle:

Principle #25Self-service

3Strength

If silane-grafted polyethylene is crosslinked using peroxide, then adhesion properties are improved, but the process complexity and cost increase

Engineering Contradiction:

Improveadhesion propertiesVSAvoidcrosslinking process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates peroxide from the crosslinking process by using alternative crosslinking methods such as moisture-curing or condensation polymerization. This removes the need for peroxide handling, storage, and application equipment, simplifying the overall process while maintaining adhesion improvements through crosslinking.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical crosslinking mechanism using peroxide with alternative crosslinking mechanisms such as silane condensation or moisture-curing reactions. This substitution eliminates the need for peroxide-based chemical systems and their associated process complexity while achieving the same adhesion enhancement through crosslinked network formation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 polymer composition significantly enhances UV protection, increases power output by reflecting photons back to the photovoltaic element, and maintains good adhesion properties, while being cost-effective and stable over time.

Implementation Method 1

the polymer composition significantly enhances UV protection, increases power output by reflecting photons back to the photovoltaic element

Methodology Applied

Scientific EffectUV absorption: Absorption (EM radiation)

Implementation Method 2

increases power output by reflecting photons back to the photovoltaic element

Methodology Applied

Scientific EffectPhoton reflection: Reflection

Implementation Method 3

The silane-grafted polyethylene or copolymer of ethylene containing silane groups containing comonomer can be then crosslinked, e.g. during or after lamination process of the photovoltaic (PV) module

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentUS11552210B2Polymer composition for photovoltaic applications

Publication Date: 2023.01.10 BOREALIS AG

AI summary

The present invention relates to a polymer composition, to an article comprising the polymer composition, preferably to an article which is a photovoltaic (PV) module comprising at least one layer element (LE) comprising the polymer composition and to a process for producing said article, preferably said photovoltaic (PV) module.