Optimization of coating formulations for protective films used in exterior applications

Surface coatings are critical for enhancement of both performance and aesthetic attributes for numerous applications; those utilized in construction of protective packaging for photovoltaic modules face particularly demanding requirements because of their long-term expected use-life (20-30 years) over a broad range of climatic environments.;Furthermore, as surface coatings represent a relatively new approach to photovoltaic protective packaging design, their adoption in the industry has entailed rigorous aesthetic inspection in addition to functional performance testing.;The goals of the present investigation were to identify key formulation and process parameters for a previously-developed chemistry platform permitting: 1. Reduction of non-uniformities in coating that can result in high manufacturing waste or customer claims; 2. Improved manufacturing throughput; 3. Raw material cost reduction; 4. Improved protective attributes of coating.;Identification and optimization of key coating formulation and process parameters yielded the following benefits: 1. 100X reduction in the frequency of select visual non-uniformities / 1% internal finished yield improvement; 2. 15% increase in manufacturing throughput via higher line-speeds; 3. 20% reduction in raw material costs for coating formulation; 4. 20% improvement in durability of protective laminate.