Flexible Solar Cell Encapsulation Using Composite Films

Solution Overview

Problem

Traditional solar cell encapsulation methods are time-consuming, result in heavy modules, and limit flexibility due to the use of glass, making them unsuitable for applications requiring lightweight and bendable solutions.

Innovation Solution

A method using composite films with different thicknesses for encapsulating solar cells without glass, employing a document/photo laminator for lamination at atmospheric pressure, allowing for lightweight, flexible, and easily connectable solar cell modules with back electrodes, enabling attachment to curved surfaces and easy replacement of faulty cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional glass plate encapsulation is used, then the solar cell module is protected, but the weight increases and flexibility is lost

Engineering Contradiction:

Improveprotection of solar cellVSAvoidmodule weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces traditional rigid glass plate encapsulation with flexible thin film encapsulation materials. These thin films provide the necessary protection for solar cells while being lightweight and flexible, enabling the module to be bent and adapted to curved surfaces without the weight and rigidity constraints of glass.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs composite encapsulation structures combining multiple materials with complementary properties. The composite design integrates the protective functions of traditional glass with the lightweight and flexible characteristics of polymer films, achieving both protection and flexibility in a single encapsulation system.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional glass plate encapsulation is used, then the solar cell module is protected, but the module becomes inflexible

Engineering Contradiction:

Improveprotection of solar cellVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces traditional rigid glass plate encapsulation with flexible thin film encapsulation materials. These thin films provide the necessary protection for solar cells while being lightweight and flexible, enabling the module to be bent and adapted to curved surfaces without the weight and rigidity constraints of glass.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs composite encapsulation structures combining multiple materials with complementary properties. The composite design integrates the protective functions of traditional glass with the lightweight and flexible characteristics of polymer films, achieving both protection and flexibility in a single encapsulation system.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If traditional encapsulation method with heating and evacuation is used, then the components are laminated, but the process is time-consuming

Engineering Contradiction:

Improvelamination of componentsVSAvoidencapsulation process time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the time-consuming heating and evacuation steps from the traditional encapsulation process. By using alternative lamination methods that do not require these steps, the process is significantly simplified and accelerated while still achieving proper bonding of the encapsulation components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs disposable adhesive tapes or films that provide temporary bonding during assembly and are then removed or remain as part of the final structure. This approach eliminates the need for complex heating and evacuation equipment and processes, dramatically reducing both equipment cost and process time.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 significantly reduces the weight of solar cell modules, enhances flexibility, and simplifies the encapsulation process, making them suitable for applications like drones while maintaining high output power and reducing the risk of cracking.

Implementation Method 1

an adhesive layer (122) between the protective layer (120) and the solar cell (10)

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the components are pressed and laminated

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11545593B2Encapsulation for solar cell and method for encapsulating solar cell

Publication Date: 2023.01.03 NAT TAIWAN UNIV

AI summary

The subject disclosure provides a simple, fast, and high-yield method for encapsulating solar cells. This method can produce an encapsulation of solar cell(s) that is flat, bubble-free, lightweight, and flexible. In addition, it can also reduce equipment and material costs.