Solar Cell Back Sheet Coating Adhesion
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Solution Overview
Problem
The existing methods for manufacturing back sheets for solar cells require additional adhesive or ground layers, leading to high costs and complexity, with pre-manufactured fluoropolymer films often being thicker than necessary, resulting in waste and increased expenses.
Innovation Solution
A back sheet comprising a substrate coated with a fluoropolymer layer containing modified resins, inorganic fillers, and solvents, cured using ultraviolet irradiation or high-energy radiation, eliminating the need for additional adhesive layers and allowing for continuous industrial production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-manufactured fluoropolymer film is laminated to polymer substrate, then adhesion between layers is achieved, but additional adhesive layers and complex manufacturing steps are required
Solution Approach 1:
The patent merges the fluoropolymer film and substrate into a single integrated layer by coating fluoropolymer directly onto the substrate and curing it, eliminating the need for separate adhesive layers and reducing manufacturing steps while maintaining strong adhesion
Solution Approach 2:
The patent extracts and removes the unnecessary adhesive layer from the traditional multi-layer structure, keeping only the essential fluoropolymer coating on the substrate, which simplifies the overall structure and manufacturing process
2Strength
If pre-manufactured fluoropolymer film is used, then sufficient strength during adhering and post-processing is achieved, but film thickness is greater than necessary, resulting in material waste
Solution Approach 1:
The patent changes the thickness parameter of the fluoropolymer layer by applying it as a thin coating that is then cured in place, allowing the layer to be much thinner than pre-manufactured films while maintaining sufficient strength through proper curing
Solution Approach 2:
The fluoropolymer coating serves its own function of providing protection and strength without requiring a thicker pre-manufactured film, as the curing process creates a sufficiently strong and durable layer at minimal thickness
3Strength
If additional adhesive layer is added to improve adhesion, then bonding strength between layers is enhanced, but manufacturing cost increases
Solution Approach 1:
The patent combines the fluoropolymer coating and substrate into a single integrated structure where the fluoropolymer is cured directly on the substrate, eliminating the need for separate adhesive materials and reducing overall manufacturing cost while maintaining 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 a cost-effective, high-performance back sheet with enhanced adhesion and weathering resistance, achieving a service life of over 25 years without the need for additional layers, and enabling simple, efficient manufacturing processes.
Implementation Method 1
the curing method includes curing by crosslinking the fluoropolymers through ultraviolet irradiation, or curing by crosslinking the fluoropolymers through high-energy radiation
Implementation Method 2
PTFE serves as a nucleating agent for curing the coating by crystallization and solidification
Data Source
AI summary
The present invention relates to a back sheet for solar cell and a method of manufacturing the same. The back sheet for solar cell comprises a substrate and a fluoropolymer layer, wherein the components by weight of the fluoropolymer layer are as follows: 25 ∼ 45 parts of fluororesin; 1.5 ∼ 3 parts of Modified resin; 0.5 ∼ 3 parts of polymeric filler; 0.1 ∼1 parts of inorganic filler; and50 ∼ 70 parts of solvent. The back sheet for solar cell provided by the present invention has low cost and excellent performances, such as high peeling strength, good waterproof performance, and good weathering resistance. The method of manufacturing the back sheet for solar cell provided by the present invention is sample in profess, and thus can achieve continuous industrial production.