Silane-Modified Polyolefin Encapsulant for Homogeneous PV Coloration
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Solution Overview
Problem
Conventional methods for manufacturing colored photovoltaic modules are complex, require additional layers that increase the risk of delamination, and are incompatible with temperature-sensitive photovoltaic technologies like perovskite and dye-sensitized cells due to high lamination temperatures.
Innovation Solution
A method involving a silane-modified polyolefin encapsulant with pigment particles and a cross-linking catalyst, processed at lower temperatures (60° C. to 125° C.) to create a homogeneous coloration without delamination issues, suitable for both conventional and temperature-sensitive PV modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lamination temperatures (130°C-170°C) are used to laminate pigment particles into the encapsulant, then the encapsulant achieves proper bonding and mechanical properties, but the pigment particles migrate during lamination causing significant non-homogeneity of coloration
Solution Approach 1:
The patent changes the lamination temperature parameter from conventional ranges (130°C-170°C) to a lower range (60°C-125°C). This parameter change prevents pigment particle migration while still achieving adequate encapsulant bonding and mechanical properties, thereby resolving the contradiction between coloration homogeneity and lamination temperature
Solution Approach 2:
The pigment particles are pre-dispersed into the encapsulant material before lamination occurs. This preliminary action ensures uniform distribution of pigments throughout the encapsulant matrix before the lamination process begins, preventing migration and ensuring homogeneous coloration at the lower lamination temperatures
2Shape
If additional coloured film layers are added to the PV module to achieve desired coloration, then the aesthetic appearance is improved, but the risk of delamination increases due to more interfaces between layers
Solution Approach 1:
The patent merges the coloration function with the encapsulant layer by incorporating pigment particles directly into the encapsulant material. This consolidation eliminates the need for separate colored film layers, reducing the number of interfaces between layers and thereby decreasing the risk of delamination while achieving the desired aesthetic appearance
Solution Approach 2:
The encapsulant layer is given multiple functions: it provides mechanical bonding between PV cells and sheets, and simultaneously provides the desired coloration through embedded pigment particles. This multi-functionality eliminates the need for additional dedicated coloration layers, reducing interface complexity and delamination risk
3Strength
If high lamination temperatures are used to process the encapsulant, then proper bonding and mechanical properties are achieved, but temperature-sensitive PV technologies like perovskite and dye-sensitized cells are damaged
Solution Approach 1:
The patent changes the lamination temperature parameter to a lower range (60°C-125°C) that is compatible with temperature-sensitive PV technologies. This parameter change enables the use of conventional lamination equipment while protecting perovskite, organic, and dye-sensitized cells from thermal damage, achieving adequate bonding and mechanical properties without excessive heat
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
This approach results in a stable, homogeneously colored photovoltaic module with improved mechanical properties and reduced energy consumption, compatible with various PV technologies, including perovskite and dye-sensitized cells, while preventing pigment migration and encapsulant flow.
Implementation Method 1
an additive comprising at least a cross-linking catalyst, said cross-linking catalyst being present in a proportion of 0.01 to 20, preferably 0.01 to 5 parts per hundred of resin
Implementation Method 2
providing a base resin comprising a silane-modified polyolefin (such as an ethylene-containing co-polymer)
Implementation Method 3
forming a mixture of said base resin, pigment particles of a convenient type, size and concentration
Implementation Method 4
laminating said first layer, said second layer and said encapsulant material under application of heat and pressure
Implementation Method 5
said heat being applied at a temperature between 60° C. and 125° C., preferably between 60° C. and 100° C., further preferably between 70° C. and 90° C.
Implementation Method 6
under application of heat and pressure
Implementation Method 7
a photovoltaic conversion device (7) comprising one or more PV cells
Data Source
AI summary
Method of manufacturing a photovoltaic module comprising at least a first layer and a second layer affixed to each other by means of an encapsulant, said method comprising a lamination step wherein the encapsulant material comprises a silane-modified polyolefin having a melting point below 90° C., pigment particles and an additive comprising a cross-linking catalyst; and wherein in said lamination step heat and pressure are applied to the module, said heat being applied at a temperature between 60° C. and 125° C.