Conductive Backsheet Production with Integrated Encapsulating Layer
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Solution Overview
Problem
Current photovoltaic panel production processes face challenges such as high variability in cell-to-module loss, complex series connection layouts, non-planar cell surfaces leading to mechanical stress, limited automation, high labor costs, and difficulties in accurately positioning encapsulating layers, resulting in low-quality and costly back-contact type panels.
Innovation Solution
An automatic production system and process for conductive backsheets with integrated encapsulating and dielectric layers, featuring a main and secondary line with calibrated superimposition and integrated control systems, enabling precise positioning and automatic assembly of conductive elements, reducing manual operations, and using a multi-layer or single-layer encapsulating and insulating film for improved quality and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual assembly processes are used for back-contact photovoltaic panels, then flexibility in handling complex configurations is maintained, but production speed is slow and labor costs are high
Solution Approach 1:
The assembly system is divided into multiple independent stations (loading station, drilling station, lamination station, cooling station, unloading station) that process different operations sequentially. This segmentation allows each station to be optimized independently while maintaining overall system productivity and enabling automated operation without requiring complex coordinated manipulation throughout the entire process.
Solution Approach 2:
The automated assembly system is designed to handle various back-contact panel configurations through programmable control. The same automated line can process different cell layouts, contact patterns, and encapsulating layer configurations by adjusting control parameters, providing universal capability without requiring manual reconfiguration for each product variant.
2Manufacturing precision
If encapsulating layers are positioned manually, then adjustment flexibility is maintained, but positioning accuracy is low and quality is poor
Solution Approach 1:
Manual mechanical positioning of encapsulating layers is replaced with an automated lamination station that uses controlled heating and pressure application. The system automatically aligns and bonds the encapsulating layers to the photovoltaic cells through programmed mechanical movement and thermal processing, achieving high positioning accuracy without complex manual alignment procedures.
Solution Approach 2:
The lamination process utilizes phase transition of the encapsulating material through controlled heating. The heating element raises the temperature to activate adhesive properties or enable thermocompression bonding, ensuring precise and reliable attachment of encapsulating layers to the cell structure without requiring complex mechanical positioning mechanisms.
3Loss of time
If silkscreen printing is used for applying insulating solutions, then conventional process compatibility is maintained, but production time increases and labor costs are high
Solution Approach 1:
The insulating solution application step is extracted and integrated into the automated lamination process. Instead of applying insulating material separately through silkscreen printing, the encapsulating layers themselves serve as the insulating barrier, and their positioning and bonding are accomplished during the automated lamination operation, eliminating the need for separate printing steps.
Solution Approach 2:
The functions of encapsulation and insulation are merged into a single integrated layer structure. The encapsulating material performs both mechanical protection and electrical insulation functions simultaneously, allowing the lamination process to achieve multiple objectives in one operation rather than requiring sequential application of separate insulating and encapsulating layers.
4Reliability
If conventional backsheet structures are used, then structural simplicity is maintained, but electrical connection reliability and protection quality are insufficient
Solution Approach 1:
The backsheet structure is designed as a composite multi-layer assembly consisting of the photovoltaic cell, conductive adhesive material, encapsulating layers, and insulating layers. This composite structure integrates multiple functions (mechanical support, electrical connection, protection, and insulation) into a unified assembly that achieves superior reliability compared to conventional single-layer backsheets, while the automated assembly process manages the complexity through standardized processing steps.
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
Automatic production system (10) and production process (20a-b) for the automatic manufacturing of conductive backsheets (300) with an integrated encapsulating and dielectric layer, for photovoltaic panels of the back-contact type. The system includes operating stations in sequence and is made up of at least one main line (11 ) combined with a secondary line (12) having a flow converging to a station of calibrated superimposition with fixing (113). The main line, on trays on a continuous conveying system, arranges and prepares the back supporting and conductive layer, whereas the secondary line forms the encapsulating and dielectric multi-layer element (308) holed in correspondence of the electrical contacts comprising an automatic picking device (126) which takes, roto-translates and holds said multi-layer element during processing and releases it only after said calibrated superimposition with fixing. The system (10) is combined with a particular control system (140) made up of at least four devices (141-4) integrated with one another to enable calibration and check the automated processes.