Solar Cell Sealing Material Composition for Low-Temperature Impact Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar battery sealing materials face challenges in achieving flexibility, stress absorbing properties, transparency, and impact-resistant strength at low temperatures, particularly due to the need for cross-linking treatments that reduce production efficiency and potentially harm solar battery elements.
Innovation Solution
A solar battery sealing material composed of specific polypropylene, propylene-ethylene-based copolymer, and ethylene-α-olefin copolymer combinations, optimized in weight ratios and properties, which eliminates the need for cross-linking treatments while enhancing flexibility, heat resistance, and impact strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cross-linking treatment is performed to improve heat resistance, then heat resistance is improved, but production time increases and production efficiency decreases
Solution Approach 1:
The patent changes the chemical composition parameters of the sealing material by specifying precise proportions of polypropylene (1-30 parts), propylene-ethylene copolymer (70-99 parts), and ethylene-alpha-olefin copolymer (5-95 parts). This compositional parameter change enables the material to achieve sufficient heat resistance without requiring cross-linking treatment, thus resolving the contradiction between heat resistance and production efficiency
Solution Approach 2:
The patent creates a composite sealing material system combining three different polymer components with specific functional characteristics. The polypropylene provides heat resistance, the propylene-ethylene copolymer provides flexibility and adhesion, and the ethylene-alpha-olefin copolymer enhances impact resistance. This composite material approach achieves multiple performance requirements simultaneously without additional cross-linking processing
2Temperature
If cross-linking treatment is performed to improve heat resistance, then heat resistance is improved, but production time increases
Solution Approach 1:
The patent extracts and eliminates the cross-linking treatment step from the manufacturing process. By formulating the sealing material with a specific composition of polymers that inherently provide heat resistance through their molecular structure and intermolecular forces, the patent removes the need for time-consuming cross-linking treatment, directly reducing production time while maintaining heat resistance
3Stability of the object's composition
If EVA is used as sealing material to achieve transparency and flexibility, then transparency and flexibility are improved, but acetic acid gas is generated during decomposition
Solution Approach 1:
The patent replaces EVA, which has decomposition issues, with a propylene-based polymer composition that offers comparable transparency and flexibility without the harmful decomposition byproduct. The specific polymer blend maintains the required optical and mechanical properties while eliminating the acetic acid gas generation problem inherent to EVA
Solution Approach 2:
The patent uses a composite of three propylene-based polymers that collectively provide transparency, flexibility, and thermal stability without generating harmful gases. The propylene-ethylene copolymer and ethylene-alpha-olefin copolymer contribute to flexibility and optical clarity, while the polypropylene base provides thermal stability, collectively replacing EVA's functional benefits without its decomposition hazards
4Productivity
If specific polymer composition is used to eliminate cross-linking treatment, then production efficiency is improved, but achieving desired flexibility and impact strength becomes challenging
Solution Approach 1:
The patent assigns specific functional roles to each polymer component based on their inherent properties. Polypropylene (1-30 parts) provides heat resistance and structural stability, propylene-ethylene copolymer (70-99 parts) provides flexibility and adhesion through its copolymer structure, and ethylene-alpha-olefin copolymer (5-95 parts) enhances impact resistance. This localized functional assignment within the composite achieves the desired flexibility and impact strength without cross-linking treatment
Data Source
AI summary
[Task] To provide a solar battery sealing material obtained by using an olefin-based (co)polymer, which is excellent in flexibility, stress-absorbing property, transparency, and impact-resistant strength at low temperature, and with which the productivity is improved by omitting a cross-linking treatment if necessary. [Solving Means] A solar battery sealing material containing 1 to 40 parts by weight of polypropylene (i) which has a propylene unit of more than 90 mol%; and 60 to 99 parts by weight of a propylene·ethylene-based copolymer (ii) which has a propylene unit of 45 to 90 mol%, an ethylene unit of 10 to 25 mol%, and an α-olefin unit (a) having 4 to 20 carbon atoms of 0 to 30 mol% ((i) + (ii) = 100 parts by weight). The solar battery sealing material further contains 5 to 95 parts by weight of an ethylene·α-olefin copolymer (B), based on 95 to 5 parts by weight of the total amount of (i) and (ii) ((i) + (ii) + (B) = 100 parts by weight).