Extruded Edge Seal for Photovoltaic Modules
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Solution Overview
Problem
Current methods for sealing and insulating the edges of photovoltaic modules, such as the 'edge delete' process, result in reduced efficiency and additional manufacturing steps, as they compromise the active area and require extra processing.
Innovation Solution
An extruded edge seal is applied using polymers, which can include a bonding layer, to simultaneously seal and insulate the edges of photovoltaic modules, allowing the active layer to extend closer to the module edges without the need for edge deletion, using an extruding device that can apply multiple polymer layers continuously around the perimeter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the edge delete process is used to seal and insulate module edges, then edge sealing and insulation are achieved, but the active area is reduced and manufacturing complexity increases
Solution Approach 1:
The edge seal is divided into multiple functional layers: a first polymer layer providing insulation and a second polymer layer providing sealing. This segmentation allows each layer to optimize its specific function while working together to solve both sealing and insulation requirements simultaneously, eliminating the need for edge delete.
Solution Approach 2:
The invention uses composite polymer materials with different properties in different layers. The first polymer is selected for insulating properties while the second polymer is selected for sealing properties. This composite structure enables simultaneous achievement of insulation and sealing functions without compromising active area.
2Reliability
If the edge delete process is used to seal and insulate module edges, then edge sealing and insulation are achieved, but additional manufacturing steps are required
Solution Approach 1:
The sealing and insulation functions that were previously separate steps are merged into a single integrated edge seal structure. The multi-layer polymer seal is applied in one continuous process, combining what were previously separate manufacturing operations into a unified solution.
Solution Approach 2:
The multi-layer polymer edge seal serves multiple functions simultaneously: it provides electrical insulation, environmental sealing, and mechanical protection all in one component. This multi-functionality eliminates the need for separate edge delete and filling operations.
3Object-affected harmful factors
If the active layer is spaced away from module edges through edge delete, then edge insulation is achieved, but the active area for light conversion is reduced
Solution Approach 1:
Instead of permanently removing active layer material, the invention uses applied polymer layers that provide the necessary insulation and sealing functions. These polymer layers are applied only where needed at the edges, preserving the bulk of the active area while providing localized protection.
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 extruded edge seal enhances efficiency by maintaining more active area for light conversion, simplifies manufacturing, and provides robust insulation and sealing without the need for additional processing steps.
Implementation Method 1
An extruding device is provided which applies the one or more polymers by extrusion around a perimeter of the photovoltaic module, thereby forming an extruded edge seal
Data Source
Figure 1A~1B
Figure 1C
Figure 1D~1E
AI summary
An edge seal extruded onto at least a portion of one or more edges of a photovoltaic module is disclosed. A method for making a photovoltaic module comprising an extruded edge seal is also disclosed.