Colored Solar Cell Lamination for Uniform Pigment Orientation
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Solution Overview
Problem
Existing methods for manufacturing encapsulated solar cell modules with effect pigments result in undesired reorientation of pigments during lamination, leading to dark patterns around cells and bus bars, which limits their use in building-integrated photovoltaics.
Innovation Solution
A modified lamination process where the polymer film with effect pigments is pre-laminated to the front sheet before assembling the solar cell stack, reducing pigment disorientation and maintaining color reflection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If effect pigments are incorporated into the encapsulant film for coloring solar cells, then color reflection and aesthetic appearance are improved, but the pigments reorient during lamination causing dark patterns and reduced color uniformity
Solution Approach 1:
The patent applies preliminary action by pre-laminating the encapsulant film containing effect pigments to the front glass sheet before assembling the complete solar module stack. This preliminary lamination step establishes the desired parallel orientation of the platelet-shaped pigments relative to the glass surface, preventing their reorientation to orthogonal positions that would cause dark patterns during subsequent lamination steps
Solution Approach 2:
The patent segments the lamination process into distinct sequential steps: first laminating the encapsulant film with effect pigments to the front glass sheet, then subsequently laminating the solar cells and other components to this pre-prepared assembly. This segmentation allows the pigment-containing film to be processed and oriented correctly before final module assembly, maintaining color uniformity
2Strength
If the encapsulant film is laminated at high temperature and pressure to ensure proper bonding, then lamination strength is improved, but the effect pigments reorient and color uniformity deteriorates
Solution Approach 1:
The patent performs the lamination of the encapsulant film containing effect pigments to the front glass sheet as a preliminary action before the main high-temperature, high-pressure lamination step that bonds all module components together. This timing allows the pigments to be fixed in their desired parallel orientation on the glass surface before subsequent processing, preventing the high energy input of final lamination from causing pigment reorientation
Solution Approach 2:
The patent provides beforehand cushioning by establishing a stable, low-energy bonding interface between the encapsulant film and front glass sheet in advance, creating a fixed reference frame that prevents pigment reorientation during subsequent high-energy lamination steps. The pre-laminated assembly acts as a protected unit that maintains pigment orientation throughout further processing
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
The method achieves improved color uniformity and stability of solar cell modules with negligible loss in efficiency, allowing for seamless integration into various surfaces without visible bus bars and enhanced long-term performance.
Implementation Method 1
The effect pigments are reflecting a part of the visible sunlight, but let pass the light needed to create energy
Implementation Method 2
The stack is then heated up e.g. to 130° C. to 160° C. (depending on the type of encapsulant material used) and pressed together by vacuum or any other type of physical pressure
Implementation Method 3
The stack is then heated up e.g. to 130° C. to 160° C. (depending on the type of encapsulant material used) and pressed together by vacuum or any other type of physical pressure
Implementation Method 4
A photoactive material absorbs light and generates an excited electron-hole pair
Data Source
AI summary
A process for the preparation of colored solar cells or colored solar cell modules containing a colored polymer film with oriented effect pigments, and colored solar cells or colored solar cell modules prepared by this process.