Curved Photovoltaic Tile Lamination for Micro-Crack Reduction
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Solution Overview
Problem
Dual-sided power-generating photovoltaic tiles using silicon crystalline cells are prone to breakage due to low strength.
Innovation Solution
A method involving two-step lamination is employed, where a first adhesive film layer, solar cell, and first protective layer are stacked and primary laminated, followed by stacking a rigid curved second protective layer and second adhesive film layer with the laminated assembly for secondary lamination, enhancing the solar cell's strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-step lamination is used to process curved photovoltaic tiles, then the processing complexity is reduced, but the bending resistance of the solar cell is insufficient, leading to micro-cracks and reduced reliability
Solution Approach 1:
The lamination process is divided into two distinct steps: first lamination to form a planar laminated assembly with the solar cell, and second lamination to form the curved structure. This segmentation allows each step to be optimized independently - the first step ensures proper solar cell embedding and initial bonding, while the second step creates the curved shape without compromising the solar cell's structural integrity, thereby improving bending resistance and reducing micro-cracks.
2Power
If silicon crystalline cells are used in dual-sided power-generating photovoltaic tiles, then power generation capability is achieved, but the cells are prone to breakage due to low strength
Solution Approach 1:
The patent employs a composite structure where the silicon crystalline cell is embedded within multiple protective layers including adhesive films and protective layers. This composite construction provides mechanical support and protection to the fragile solar cell, enhancing its strength and resistance to breakage while maintaining its power generation functionality. The layered composite structure distributes stress and protects the cell from direct mechanical impacts.
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 improves the bending resistance of the solar cell, reducing the probability of micro-cracks and enhancing the stability and reliability of the curved photovoltaic tile.
Implementation Method 1
the first adhesive film layer softens upon heating and adheres to the solar cell
Implementation Method 2
the first adhesive film layer softens upon heating and adheres to the solar cell
Data Source
AI summary
Provided are a method for processing a curved photovoltaic tile, and a curved photovoltaic tile. The method for processing the curved photovoltaic tile, includes: stacking a first adhesive film layer, a solar cell, and a first protective layer on each other in sequence; performing a primary lamination on the first adhesive film layer, the solar cell, and the first protective layer to form a planar laminated assembly; stacking a rigid curved second protective layer, a second adhesive film layer, and the laminated assembly on each other in sequence; and performing a secondary lamination on the second protective layer, the second adhesive film layer, and the laminated assembly to form the curved photovoltaic tile.