Co-Extruded Polymer Photovoltaic Panels
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Solution Overview
Problem
The existing production processes for photovoltaic panels are costly and laborious, and the use of silicon-based technologies has limitations due to high costs and environmental concerns, while alternative materials like conductive polymers have shorter lifespans and lower energy yields.
Innovation Solution
A photovoltaic panel production process using direct co-extrusion of polymeric materials to form multilayer panels with transparent and conductive polymer layers, incorporating amorphous PET, Polyolefins, and other polymers with photoactive fillers or nanofillers, allowing for cost-effective and flexible panel production with opaque conductive polymers and undulated surfaces for enhanced radiation concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional silicon-based photovoltaic panels are used, then energy yield and reliability are improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent changes the material parameters from crystalline silicon to amorphous silicon and conductive polymers, enabling production through co-extrusion processes that reduce manufacturing complexity and cost while maintaining functional performance
Solution Approach 2:
The patent employs cheaper alternative materials (amorphous silicon, conductive polymers) that can be produced through simpler, more cost-effective co-extrusion processes, accepting slightly reduced lifespan in exchange for significant cost reduction
2Ease of manufacture
If thin film deposition is used to optimize silicon usage, then production cost is reduced, but material durability and energy yield decrease
Solution Approach 1:
The patent creates composite multilayer structures combining amorphous silicon layers with conductive polymer layers, where each material compensates for the other's weaknesses - the polymers provide flexibility and cost-effectiveness while the amorphous silicon maintains photovoltaic functionality
Solution Approach 2:
The patent transitions from thin film deposition to co-extrusion processing, changing the manufacturing parameter to achieve better material integration and durability while maintaining cost effectiveness
3Ease of manufacture
If opaque conductive polymers are used, then manufacturing simplicity is improved, but light transmission to semiconductor layers is reduced
Solution Approach 1:
The patent introduces undulated surface geometry as an additional dimension, using surface topology to redirect and concentrate light onto the semiconductor layers, compensating for the opacity of the conductive polymer layers
Solution Approach 2:
The patent employs curved/undulated surface profiles on the conductive polymer layers to optimize light path routing, ensuring maximum light concentration on the photovoltaic active layers despite the opaque nature of the polymers
4Use of energy by moving object
If undulated surfaces are created for radiation concentration, then energy efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the undulated surface geometry directly into the co-extrusion molding process, integrating the optical concentration feature into the base manufacturing step rather than requiring separate post-processing operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process simplifies and reduces the cost of photovoltaic panel production, enabling the creation of flexible, cost-effective panels with improved mechanical resistance and efficiency, making photovoltaic energy more competitive with conventional sources.
Implementation Method 1
The operation of a photovoltaic panel is based upon the homonymous effect which occurs when an electron in the valence band of a (generally semiconductive) material passes to the conduction band due to the absorption of a sufficiently energetic photon, incident on the material
Implementation Method 2
the presence of which serves to concentrate the radiation incident on the photovoltaic layers
Data Source
Figure 1~3
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Figure 5
AI summary
The present invention concerns a photovoltaic panel (10) made through direct co-extrusion of a plurality of superimposed polymeric layers, the invention also concerns a process for producing a photovoltaic panel and a plant for carrying out such a process.