Crack-Resistant Solar Modules for Enhanced Durability
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Summary
Problems
Solar cell modules are prone to developing fern cracks due to rough handling during shipping, installation, and maintenance, which can lead to power loss and increased risk of damage.
Innovation solutions
A crack-resistant solar cell module structure featuring a protective package with a polyolefin encapsulant having less than 5 weight percent of oxygen and nitrogen in its molecular structure and a complex viscosity less than 10,000 Pa·s at 90°C, combined with a transparent top cover and backsheet, to provide environmental protection and mechanical support.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If conventional packaging materials are used, then manufacturing cost is reduced, but solar cells are prone to fern cracks during handling
Why choose this principle:
The patent applies parameter changes by specifying precise chemical composition parameters for the polyolefin encapsulant (less than 5 weight percent oxygen and nitrogen in the backbone or side chain) and rheological parameters (complex viscosity less than 10,000 Pa·s at 90°C). These parameter specifications transform the encapsulant material properties to achieve superior crack resistance while maintaining manufacturability through controlled material selection.
Principle concept:
If conventional packaging materials are used, then manufacturing cost is reduced, but solar cells are prone to fern cracks during handling
Why choose this principle:
The patent employs composite materials by formulating a polyolefin encapsulant with specific compositional characteristics (low oxygen and nitrogen content) combined with controlled molecular weight distribution to achieve optimal viscosity. This composite approach integrates multiple material properties to simultaneously provide mechanical protection and processing ease.
Application Domain
Data Source
AI summary:
A crack-resistant solar cell module structure featuring a protective package with a polyolefin encapsulant having less than 5 weight percent of oxygen and nitrogen in its molecular structure and a complex viscosity less than 10,000 Pa·s at 90°C, combined with a transparent top cover and backsheet, to provide environmental protection and mechanical support.
Abstract
A crack resistant solar cell module includes a protective package mounted on a frame. The protective package includes a polyolefin encapsulant that protectively encapsulates solar cells. The polyolefin has less than five weight percent of oxygen and nitrogen in the backbone or side chain. In other words, the combined weight percent of oxygen and nitrogen in any location in the molecular structure of the polyolefin is less than five. The polyolefin also has a complex viscosity less than 10,000 Pa second at 90° C. as measured by dynamic mechanical analysis (DMA) before any thermal processing of the polyolefin. The protective package includes a top cover, the encapsulant, and a backsheet. The solar cell module allows for shipping, installation, and maintenance with less risk of developing cracks on the surfaces of the solar cells.