Curved Photovoltaic Module Encapsulation for Stress Dispersion
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Solution Overview
Problem
Curved photovoltaic modules using crystalline silicon solar cells face issues with stress concentration and uneven deformation leading to hard contact, causing fragmentation and hidden cracks due to the brittleness of the solar cells.
Innovation Solution
A curved photovoltaic module design incorporating a solar cell unit sandwiched between two encapsulant film layers and curved glass and back panel, with specific thicknesses and materials to disperse stress and prevent hard contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If crystalline silicon solar cells are bent to create curved photovoltaic modules, then power generation efficiency is improved, but stress concentration and uneven deformation occur causing fragmentation and hidden cracks
Solution Approach 1:
The patent applies beforehand cushioning by introducing a buffer layer between the solar cell and the curved substrate before bending. This buffer layer pre-compensates for the stress that will occur during bending, preventing stress concentration and uneven deformation. The buffer layer is positioned in advance to cushion the solar cell during the curvature formation process, thereby maintaining structural integrity while achieving the desired curved shape for improved power generation efficiency.
Solution Approach 2:
The patent employs parameter changes by modifying the mechanical properties of the encapsulant material. The encapsulant is designed with specific elasticity modulus and thickness parameters that allow it to deform uniformly during bending while protecting the solar cell. By changing the material parameters (selecting materials with appropriate elastic moduli and configuring thickness ratios), the system achieves both the required curvature and stress distribution to prevent fragmentation.
2Shape
If the solar cell is bent with uneven deformation, then curvature is achieved, but hard contact occurs between local parts and glass or back panel causing fragmentation
Solution Approach 1:
The patent applies local quality by making the buffer layer's thickness non-uniform across the solar cell surface. The buffer layer is thicker at regions prone to higher stress concentration (such as edges or centers depending on curvature radius) and thinner in other areas. This localized variation in buffer layer quality compensates for uneven deformation tendencies, ensuring uniform stress distribution and preventing hard contact between the solar cell and the curved substrate while achieving the desired overall curvature.
3Adaptability or versatility
If thin-film technology is used for curved photovoltaic products, then flexibility is achieved, but conversion efficiency is low and cost is high
Solution Approach 1:
The patent uses flexible shells and thin films by implementing a thin buffer layer and flexible encapsulant material between the rigid crystalline silicon solar cell and the curved substrate. This thin film structure allows the overall assembly to be bent into curved shapes while the buffer layer prevents stress transmission to the solar cell. This approach achieves the flexibility and adaptability of thin-film technology while maintaining the high conversion efficiency of crystalline silicon solar cells.
Data Source
AI summary
Provided is a curved photovoltaic module. The curved photovoltaic module includes a solar cell unit, and curved glass and a curved back panel that are disposed at both sides of the solar cell unit. A first encapsulant film layer is arranged between the curved glass and the solar cell unit. A second encapsulant film layer is arranged between the curved back panel and the solar cell unit. The first encapsulant film layer has a thickness ranging from 0.8 mm to 2 mm. The second encapsulant film layer has a thickness ranging from 0.8 mm to 2 mm.