Integrated Back-Sheet Assembly Alignment for PV Modules
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Solution Overview
Problem
The alignment of openings in encapsulant and interlayer dielectric (ILD) layers with electrically conductive circuits and back contacts on back-contact photovoltaic cells is challenging due to flexibility issues in these layers, leading to difficulties in forming reliable electrical connections during the lamination process of photovoltaic modules.
Innovation Solution
A process involving a substrate with a conductive metal circuit, release pads, and an insulating layer, where openings in the insulating layer are formed to align with the release pads and filled with conductive material, allowing for secure electrical contact between the back contacts of solar cells and the metal circuit, enhancing alignment and adhesion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If encapsulant and ILD layers are made flexible for lamination processing, then ease of manufacture is improved, but alignment precision of openings with electrical contacts deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming openings in the encapsulant and ILD layers before lamination, and pre-positioning electrical contacts on the backsheet. This ensures that when the layers are later laminated together, the openings are already aligned with the contacts, eliminating alignment issues caused by layer flexibility during the lamination process.
2Adaptability or versatility
If multiple separate layers (encapsulant, ILD, backsheet) are used, then functional requirements are met, but device complexity increases
Solution Approach 1:
The patent merges the encapsulant layer, ILD layer, and backsheet into a single integrated multilayer structure. This integration maintains all necessary functional requirements (encapsulation, insulation, structural support) while reducing the number of separate components and simplifying the overall device architecture.
3Loss of energy
If electrical contacts are placed on the back side of photovoltaic cells, then shading loss is reduced, but alignment difficulty with conductive circuits increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning electrical contacts on the backsheet and pre-forming openings in the encapsulant and ILD layers to match these contact positions. This preliminary alignment ensures that when the photovoltaic cells are installed, their back-side electrical contacts automatically align with the conductive circuits, eliminating alignment difficulties while maintaining the energy efficiency benefits of back-side contacts.
Data Source
AI summary
A process for forming a back-sheet assembly for a photovoltaic module having multiple solar cells with back-side electrical contacts includes providing a substrate, adhering an electrically conductive metal circuit to the substrate, adhering release pads to the metal circuit in a pattern, adhering an insulating layer to the metal circuit, forming openings in said insulating layer in a pattern over the release pads, and filling the openings with electrically conductive material that is in electrical contact with the electrically conductive metal circuit. A process for forming a photovoltaic module with this back-sheet assembly is also provided. The back-sheet assembly and photovoltaic module made with the back-sheet assembly are also provided.