Curved Solar Panel Lamination With Preformed Substrates
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Solution Overview
Problem
The manufacturing of solar panels with complex geometries is challenging due to stress and thermal issues, leading to premature failure, and existing methods fail to efficiently produce curved solar panels that can withstand environmental factors like moisture ingress and impact, while also being suitable for use in electric vehicles where weight and efficiency are critical.
Innovation Solution
A continuous manufacturing plant process using thin, rigid preforms made of glass or polymer to gently bend solar cells along orthogonal directions, with a flexible adhesive layer for encapsulation, and a lamination stack design that reduces thermal stress and water ingress, enhancing the solar panel's durability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If solar cells are forced to deform to complex curved surfaces, then the solar panel can match complex geometries, but internal stresses exceed the ultimate strength of the material leading to brittle failure
Solution Approach 1:
The substrate is pre-formed into the desired curved shape before solar cells are attached. This preliminary shaping of the substrate allows the cells to be mounted on a pre-configured surface rather than forcing the cells themselves to deform, thereby maintaining cell structural integrity while achieving complex panel geometries
Solution Approach 2:
A flexible substrate acts as an intermediary between the flat solar cells and the desired curved panel shape. The substrate can be pre-formed to complex geometries and provides a compliant mounting surface that accommodates curved configurations without transmitting excessive stress to the rigid solar cells
2Shape
If solar panels include layers of dissimilar materials to achieve complex shapes, then the panel can match desired geometries, but thermal expansion mismatch causes stress and potential failure
Solution Approach 1:
The patent modifies the thermal and mechanical parameters of the laminate system by using a flexible substrate with controlled expansion properties and by optimizing layer thicknesses and material selections to minimize thermal stress. The curing process parameters are also optimized to reduce thermal gradients and stress development
3Ease of manufacture
If standard lamination processes are used for curved solar panels, then production can proceed with existing equipment, but the process is time-consuming and produces surface waviness
Solution Approach 1:
The substrate is pre-formed into the desired curved shape before lamination, and release patterns are pre-applied to the substrate surface. This preliminary preparation enables faster lamination processing without requiring complex in-process adjustments, thereby improving productivity while maintaining ease of manufacture with standard equipment
Solution Approach 2:
The patent replaces complex mechanical alignment and forming systems with a simpler process using pre-formed substrates and release patterns. This substitution eliminates the need for complex mechanical adjustment mechanisms while achieving consistent curved panel formation with standard lamination equipment
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 process enables the production of solar panels with improved adhesion, reduced surface waviness, and increased durability, capable of withstanding hail impacts and environmental wear, while optimizing manufacturing efficiency and reducing production time and costs.
Implementation Method 1
an adhesive layer (124) is disposed on the substrate (120), such that the adhesive layer (124) bonds the solar cell array (200) to the substrate (120)
Implementation Method 2
a first lamination stack is formed
Data Source
AI summary
The invention relates to improved methods and implementation of reliably manufacturing laminated solar panel products having one or more axis of curvature, wherein at least one solar cell also has one or more axis of curvature, in a manufacturing plant, the manufacturing plant being capable of continuous, optimized operation. A substrate and a superstrate having a doubly-curved geometry may be assembled with a core disposed therebetween, the core comprising a solar cell array including at least one solar cell. During the lamination process, the plant substantially eliminates cracking of the at least one solar cell of the solar array through controlled and uniform application of lamination pressure and temperature that applies uniform local pressure simultaneously to each cell, resulting in a durable and reliable product. The invention further relates to a plant and/or facility having efficient, effective, and repeatable results relating to such methods.