Crack Resistant Solar Cell Modules Using Low Oxygen Nitrogen Polyolefin
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Solution Overview
Problem
Solar cell modules are prone to developing fern cracks due to rough handling during shipping, installation, and maintenance, which can lead to power loss and increased risk of damage.
Innovation Solution
A crack-resistant solar cell module design featuring a protective package with a polyolefin encapsulant having less than 5 weight percent of oxygen and nitrogen in its molecular structure and a complex viscosity less than 10,000 Pa·s at 90°C, combined with a transparent top cover and backsheet, to provide mechanical and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging materials are used, then manufacturing cost is reduced, but solar cells develop cracks during handling
Solution Approach 1:
The patent applies parameter changes by specifying precise chemical composition parameters of the polyolefin encapsulant (less than 5 weight percent oxygen and nitrogen in the backbone or side chain) and rheological parameters (complex viscosity less than 10,000 Pa·s at 90°C). These parameter specifications ensure the encapsulant provides optimal crack resistance while maintaining manufacturability through controlled material properties.
Solution Approach 2:
The patent employs composite materials by formulating a polyolefin encapsulant with specific compositional characteristics (low oxygen and nitrogen content) combined with controlled molecular weight and viscosity properties. This creates a composite material system that integrates multiple functional requirements: mechanical protection, flexibility for handling, and resistance to crack propagation.
2Strength
If rigid packaging is used, then crack protection is improved, but flexibility during installation deteriorates
Solution Approach 1:
The patent applies flexible shells and thin films by using a polyolefin encapsulant that forms a flexible protective layer around the solar cells. The encapsulant's controlled viscosity and molecular structure enable it to provide strength while maintaining flexibility, allowing the packaging to conform to solar cell shapes and accommodate handling operations without rigid constraints.
Solution Approach 2:
The patent uses parameter changes by adjusting the polyolefin's complex viscosity to less than 10,000 Pa·s at 90°C and controlling the oxygen and nitrogen content. These parameter adjustments create a material that transitions between rigid protective states and flexible handling states, enabling both crack protection and installation flexibility.
3Stability of the object's composition
If high viscosity encapsulant is used, then structural stability is improved, but crack resistance during thermal processing deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the polyolefin's complex viscosity parameter (less than 10,000 Pa·s at 90°C) and chemical composition (oxygen and nitrogen content). This creates an optimal balance where the encapsulant maintains structural stability at lower temperatures while exhibiting sufficient flexibility at processing temperatures to prevent crack development during thermal lamination.
Data Source
AI summary
A crack resistant solar cell module includes a protective package mounted on a frame. The protective package includes a polyolefin encapsulant that protectively encapsulates solar cells. The polyolefin has less than five weight percent of oxygen and nitrogen in the backbone or side chain. In other words, the combined weight percent of oxygen and nitrogen in any location in the molecular structure of the polyolefin is less than five. The polyolefin also has a complex viscosity less than 10,000 Pa second at 90° C. as measured by dynamic mechanical analysis (DMA) before any thermal processing of the polyolefin. The protective package includes a top cover, the encapsulant, and a backsheet. The solar cell module allows for shipping, installation, and maintenance with less risk of developing cracks on the surfaces of the solar cells.