Urethane-Modified Acrylate Solar Connection Material
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Solution Overview
Problem
Conventional electrical connection materials for solar cells face challenges in maintaining reliability due to stress caused by differing linear expansion coefficients between conductive wires and silicon substrates, leading to potential breakage and separation during heating and cooling cycles.
Innovation Solution
An electrical connection material comprising 40 wt % to 80 wt % urethane-modified acrylate resin, with a polymer binder resin, radical polymerizable compound, organic peroxide, and conductive particles, exhibiting tensile elongation of 100% to 500% and yield point strain of 10% to 50%, which minimizes stress and enhances reliability by forming a durable connection within 5 seconds or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrical connection materials are used to connect conductive wires to silicon substrates, then the connection can be formed quickly, but the connection reliability deteriorates due to stress from differing linear expansion coefficients during heating and cooling cycles
Solution Approach 1:
The patent changes the physical and chemical parameters of the connection material by using a two-part system: Part A contains a silane-modified polymer and silane crosslinking agent, while Part B contains a crosslinking catalyst. When mixed, these components undergo crosslinking reactions that fundamentally alter the material's properties, creating a cured product with optimized elasticity and stress resistance. This parameter transformation enables the material to maintain connection reliability while allowing for rapid initial bonding.
Solution Approach 2:
The patent employs a composite material system combining multiple functional components: silane-modified polymer (for base elasticity), silane crosslinking agent (for stress resistance through crosslinking), and crosslinking catalyst (for curing). This composite approach creates a multi-functional connection material that simultaneously provides rapid bonding capability and long-term reliability under thermal stress, resolving the contradiction between productivity and reliability.
2Reliability
If the connection material has high elasticity to withstand thermal stress, then the connection reliability improves, but the material strength may deteriorate
Solution Approach 1:
The silane-modified polymer in Part A provides beforehand cushioning by incorporating silane groups that are prepared to undergo crosslinking reactions. This pre-prepared structure allows the material to initially accommodate thermal stress through elastic deformation, while the subsequent crosslinking provides strength reinforcement. The cushioning effect is built into the material structure before final curing, enabling it to withstand thermal cycling without compromising ultimate strength.
Solution Approach 2:
The connection material exhibits dynamic properties through its two-stage behavior: initially, it maintains high elasticity to accommodate thermal expansion differences and provide stress cushioning; after crosslinking curing, it develops enhanced strength through the formed crosslinked network. This dynamic transformation from elastic-dominated to crosslinked-strength-dominated behavior allows the material to satisfy both reliability and strength requirements at different stages of service.
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 material ensures improved connection reliability and durability by maintaining contact resistance and withstanding thermal stress, outperforming conventional materials in high-temperature and high-humidity conditions and thermal shock tests.
Implementation Method 1
a polymer binder resin, a radical polymerizable compound, an organic peroxide
Implementation Method 2
an organic peroxide, and conductive particles
Data Source
AI summary
An electrical connection material between conductors includes about 40 wt % to about 80 wt % of a urethane-modified acrylate resin, based on a total weight of the electrical connection material, the electrical connection material exhibiting, after curing, a tensile elongation of about 100% to about 500% and a yield point strain of about 10% to about 50% in a stress-strain curve.