Development and Die-Cutting Process Optimization of High-Temperature-Resistant and Anti-Aging Barcode Substrate for Photovoltaic Modules

This study addresses the durability issues of barcode substrates for photovoltaic (PV) modules under extreme conditions such as high temperature, high humidity, and intense ultraviolet (UV) radiation. A three-layer structured barcode substrate with high-temperature resistance and anti-aging properties was developed, and the die-cutting process was optimized. The three-layer structure consists of a polyethylene terephthalate (PET) substrate layer, a polyimide (PI) anti-aging layer, and a wear-resistant coating. The synergistic effect of these layers significantly enhances the substrate’s temperature resistance and anti-aging performance. Experimental results indicate that after 100 thermal cycles, the tensile strength retention rate of the three-layer structured substrate reaches 92%, much higher than the 65% of traditional PET substrate. After 1000 hours of UV irradiation, the color difference (ΔE) is only 1.5, compared to the 4.0 of traditional PET substrate. Following the optimization of the die-cutting process, the burr rate was reduced from 8% to 0.5%, and the material utilization rate increased from 82% to 95%. In the pilot application at Mingyang Smart and the long-term testing in desert power stations, the three-layer structured barcode substrate demonstrated excellent performance, with a barcode integrity rate of 98%, significantly higher than the 70% of traditional PET substrate. This study provides significant technical support for the development of barcode substrates for PV modules, promoting the high-quality development of the PV industry.