Back-Contact PV Module Support Layer to Prevent Cell Scratches
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Back-contact solar cells are prone to scratches during transfer due to direct contact with a transfer table, affecting their appearance and performance.
Innovation Solution
A transparent support layer is applied to the front surface of back-contact solar cells, protruding from the surface and covering a partial region, made of materials like insulating adhesive, hot melt adhesive, or polyethylene terephthalate, to create a gap between the cell and the transfer table, reducing the risk of scratches and improving light transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the front surface of back-contact solar cells is directly transferred without protection, then the transfer process is simple and efficient, but the front surface is prone to scratches and damage
Solution Approach 1:
A transparent support layer is introduced as an intermediary protective element between the front surface of the back-contact solar cell and the transfer table. This support layer prevents direct contact during transfer operations, eliminating scratches while maintaining process simplicity. The layer is transparent to allow light transmission and can be removed or integrated into the final module structure.
2Reliability
If a transparent support layer is added to protect the front surface, then scratch risk is reduced, but light transmittance may be affected
Solution Approach 1:
The support layer is designed with high optical transparency and specific optical properties (anti-reflective characteristics) to minimize light absorption and reflection losses. By optimizing the material's optical properties, the layer provides mechanical protection while maintaining high light transmittance, ensuring minimal impact on photoelectric conversion efficiency.
3Reliability
If the transparent support layer covers a larger area of the front surface, then protection is improved, but light absorption increases and transmittance decreases
Solution Approach 1:
The transparent support layer is applied selectively to specific high-risk areas of the front surface rather than covering the entire surface uniformly. This localized application provides protection where scratches are most likely to occur during transfer and handling, while minimizing the total area that could absorb light, thus balancing protection needs with optical performance.
Data Source
AI summary
A back-contact photovoltaic module and a manufacturing method thereof. The back-contact photovoltaic module includes a glass substrate, an upper adhesive film layer, a solar cell layer, a lower adhesive film layer, and a back sheet arranged in sequence from top to bottom. The solar cell layer includes a plurality of back-contact solar cells, and each of the plurality of back-contact solar cells comprises a front surface provided with a transparent support layer. The transparent support layer protrudes from a corresponding front surface, and the transparent support layer covers a partial region of the corresponding front surface. Accordingly, the front surface of each of the plurality of back-contact solar cells can be protected, and the risk of scratches to the back-contact photovoltaic module reduced.