Vinyl Fluoride Copolymer Coating for Photovoltaic Modules
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Solution Overview
Problem
Existing methods for producing fluoropolymer laminates for photovoltaic modules require preformed films, adhesive layers, and costly equipment, leading to thick fluoropolymer layers and high manufacturing costs, while also facing challenges in long-term delamination resistance under outdoor exposure.
Innovation Solution
A fluoropolymer coated film comprising a polymeric substrate with a vinyl fluoride copolymer coating that includes functional groups for bonding, allowing for cross-linking without separate primers or adhesives, and a process for applying a liquid fluoropolymer coating composition that is cross-linked to form a durable, thin protective layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If preformed fluoropolymer films are used for laminates, then strength and handling capability are improved, but fluoropolymer layer thickness increases and manufacturing cost rises
Solution Approach 1:
The invention changes the physical state of fluoropolymer from preformed solid films to coating solutions that can be applied in controlled thin layers, then crosslinked to achieve the desired strength without excessive thickness
Solution Approach 2:
The invention creates a composite system combining fluoropolymer coating with crosslinking agents and initiators, forming a bonded network structure that provides both strength and adhesion while maintaining thin layer thickness
2Reliability
If adhesive layers and primers are applied to preformed films, then bond durability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges the functions of adhesive, primer, and fluoropolymer coating into a single integrated coating layer that bonds directly to the substrate while providing protective fluoropolymer properties
Solution Approach 2:
The coating system is self-sufficient, containing all necessary components (fluoropolymer, crosslinking agents, initiators) within a single coating formulation that performs multiple functions without requiring separate primer or adhesive layers
3Strength
If heat and pressure are applied for lamination, then bond strength is improved, but energy consumption and equipment requirements increase
Solution Approach 1:
The invention replaces mechanical lamination (heat and pressure) with a chemical bonding mechanism where crosslinking agents form covalent bonds between the coating and substrate, requiring minimal energy input
4Reliability
If multiple coating layers are applied, then protective performance is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention combines multiple protective functions (adhesion, protection, durability) into a single multi-functional coating layer that eliminates the need for separate primer and 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 solution provides a cost-effective, durable, and thin fluoropolymer coating that enhances the longevity and performance of photovoltaic modules by promoting strong bonding between the fluoropolymer and substrate, reducing delamination risks and manufacturing costs.
Implementation Method 1
a vinyl fluoride copolymer coating that is cross-linked
Implementation Method 2
the polymeric substrate film comprises functional groups that interact with the functional groups of the vinyl fluoride copolymer to promote bonding of the fluoropolymer coating to the polymeric substrate film
Data Source
AI summary
The invention provides a fluoropolymer coated film comprising:a polymeric substrate film; anda fluoropolymer coating on the polymeric substrate film, the fluoropolymer coating comprising a vinyl fluoride copolymer comprised of about 40 to about 90 mole % of repeat units derived from vinyl fluoride and about 10 to about 60 mole % of repeat units derived from monomer selected from the group consisting of (a) and (b) below and mixtures thereof, with the proviso that about 0.1 mole % to 50 mole % of repeat units in the copolymer are derived from monomer selected from (b):(a) monomer selected from the group consisting of, tetrafluoroethylene, trifluoroethylene, chlorotrifluoroethylene and mixtures thereof; and(b) vinyl monomer containing at least one functional group selected from the group consisting of hydroxyls, thiols, carbonyls, carboxylic acids, carboxylic esters, acid anhydrides, sulfonyls, sulfonic acids, sulfonic esters, phosphoric acids, phosphoric esters, boric acids, boric esters, epoxies, isocyanates, thiocyanates, amines, amides, nitriles and halogen selected from bromide and iodide,wherein the polymeric substrate film comprises functional groups that interact with the functional groups of the vinyl fluoride copolymer to promote bonding of the fluoropolymer coating to the polymeric substrate film.