Back-Contact PV Module Front-Surface Support Against Scratches
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Solution Overview
Problem
Back-contact solar cells are prone to scratches on their front surface during transfer due to direct contact with a transfer table, affecting appearance and performance.
Innovation Solution
A transparent support layer is applied to the front surface of back-contact solar cells, protruding and covering a partial region to prevent direct contact with the transfer table, made of materials like insulating adhesive, PET, EVA, or POE, with evenly distributed bumps or continuous structures to provide support and minimize light absorption.
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 solar cell and the transfer table. This support layer prevents direct contact during transfer operations, eliminating scratches while maintaining process simplicity. The support layer can be a transparent adhesive film or other transparent protective materials that are applied to the front surface before transfer.
2Reliability
If a transparent support layer is added to protect the front surface, then scratch resistance is improved, but light transmittance may be reduced
Solution Approach 1:
The support layer is designed as a thin transparent film or coating that provides mechanical protection while minimizing optical interference. By using thin film technology, the protective function is achieved with minimal impact on light transmittance, as the thin structure allows most light to pass through without significant absorption or scattering.
Solution Approach 2:
The support layer is designed to be optically transparent or have optical properties matched to the solar cell's anti-reflective coating. This ensures that the protective layer does not create noticeable optical losses or visual defects, maintaining both aesthetic appearance and photovoltaic performance.
3Reliability
If the transparent support layer covers the entire front surface, then protection is maximized, but manufacturing complexity and material usage increase
Solution Approach 1:
The transparent support layer is selectively applied only to critical areas of the front surface that are most susceptible to damage during transfer, such as the center region or areas with higher stress concentration. This localized protection approach reduces material consumption and simplifies the manufacturing process while still providing adequate protection where it is most needed.
Data Source
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AI summary
The present disclosure provides 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 back-contact solar cells, and a front surface of each of the back-contact solar cells is provided with a transparent support layer. The transparent support layer protrudes from a surface of the back-contact solar cell, and the transparent support layer covers a partial region of the front surface. According to the present disclosure, the front surface of the back-contact solar cell can be protected, and a risk of scratches to the back-contact photovoltaic module can be reduced.