Photovoltaic Backboard Repair Tape With Weather-Resistant Adhesive
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Solution Overview
Problem
Existing methods for repairing damaged solar backboards in photovoltaic modules are costly, environmentally unfriendly, and require whole module replacement, leading to inefficiencies and pollution, with no effective on-site, waste-free solutions available.
Innovation Solution
A high-performance repair tape for photovoltaic module backboards comprising a polyester thin film base material layer, a high weather-resistance adhesive layer, and a release material layer, featuring ultraviolet resistance, damp heat resistance, and ultraviolet blocking properties, along with specific adhesive and coating components for strong bonding and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the damaged solar module is replaced as a whole, then the safety and function requirements are met, but the cost increases extremely high and environmental pollution is caused
Solution Approach 1:
The invention divides the repair task into segments by applying repair tapes only to the damaged portions of the backboard rather than replacing the entire module. The backboard is treated as a composite structure where only specific damaged areas need reinforcement, allowing selective repair of affected regions while preserving functional intact areas.
Solution Approach 2:
The invention recovers and reuses the majority of the solar module by repairing only the damaged backboard areas with adhesive tapes. This approach discards the notion of whole-module replacement and instead recovers the functional value of undamaged components, reducing waste and environmental pollution while maintaining module performance.
2Reliability
If the damaged solar module is replaced as a whole, then the safety and function requirements are met, but the cost increases extremely high
Solution Approach 1:
The repair solution segments the repair process into localized applications of adhesive tapes on damaged backboard areas rather than whole-module replacement. This segmentation reduces material costs, labor costs, and logistics expenses associated with transporting and installing complete replacement modules.
Solution Approach 2:
The invention uses relatively simple and inexpensive adhesive tape materials to repair the backboard instead of investing in expensive replacement modules. The repair tapes provide sufficient durability for their intended purpose at a fraction of the cost of complete module replacement, making the repair economically viable.
3Strength
If a repair tape with strong adhesive strength is used, then the bonding reliability is improved, but the tape may cause yellowing or degradation under UV exposure
Solution Approach 1:
The repair tape employs a composite structure combining polyester base material with fluorine-containing polymer coatings. This composite design integrates the high adhesive strength of the polyester substrate with the UV resistance and weathering protection of the fluorine coating layer, achieving both strong bonding and long-term durability under outdoor conditions.
Solution Approach 2:
The invention modifies the chemical composition parameters of the adhesive and coating materials by incorporating fluorine-containing polymers and specific UV stabilizers. These parameter changes enhance the material's resistance to yellowing and degradation from UV exposure while maintaining or improving adhesive performance through optimized molecular structures and cross-linking mechanisms.
4Strength
If a thick adhesive layer is used to ensure strong bonding, then the adhesive strength is improved, but the tape becomes less flexible and harder to apply
Solution Approach 1:
The repair tape utilizes a thin-film adhesive layer design that maintains flexibility and ease of application. The adhesive layer is formulated to achieve sufficient bonding strength at reduced thickness through high-performance adhesive chemistry, allowing the tape to conform to curved or irregular backboard surfaces while providing reliable adhesion without the rigidity problems associated with thick adhesive layers.
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 repair tape provides water resistance, insulation, and ultraviolet radiation resistance, maintaining adhesive strength and preventing yellowing, while being easy to apply and cost-effective, thus extending the operational life of damaged modules without environmental harm.
Implementation Method 1
both the weather-resistant polymer film and the polymer weather-resistant coating layer have the functions of ultraviolet resistance, damp heat resistance and ultraviolet blocking
Implementation Method 2
a double-sided pressure-sensitive sheet having a first pressure-sensitive adhesive surface that adheres to the first hard object and a second pressure-sensitive adhesive surface that adheres to the second hard object
Implementation Method 3
the functional adhesive layer being made up of a high weather-resistance adhesive
Data Source
Figure 1
AI summary
Disclosed is a high-performance repair tape for a backboard of a photovoltaic module. The tape comprises a base material layer, a functional adhesive layer, and a release material layer provided in sequence from top to bottom; the base material layer is formed of a polyester thin film material; the functional adhesive layer is formed of a high weather-resistance adhesive. According to the high-performance repair tape for a backboard of a photovoltaic module, and a manufacturing method therefor provided by the present invention, by selecting a weather-resistant base material layer, effects, such as water resisting, insulation, and ultraviolet radiation resistance, can be achieved, and a backboard independence effect is achieved; by selecting a weather-resistant adhesive for the functional adhesive layer, the weather resistance, high temperature resistance, and yellowing resistance of the tape can be improved; the tape has a strong bonding strength and is not easy to peel off, and the tape is easy to fit and facilitates construction.