Flexible Thin Film Solar Module Cutting and Encapsulation
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Solution Overview
Problem
The manufacture of flexible, thin film solar modules is inflexible and expensive due to limitations in cutting and encapsulation processes, which restrict module length and shape, and require specialized equipment, with existing inks and lamination methods compromising device performance and allowing ingress of oxygen and moisture.
Innovation Solution
A method for cutting flexible, thin film electronic devices from a roll that allows for variable module length and shape, including fragmentation or delamination of electrode layers at the edges to prevent electrical shorting, and roll-to-roll encapsulation using standard equipment to prevent oxygen and water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate bottom electrodes and top electrodes are provided along the web direction with gaps between them, then individual sheets can be cut from the roll, but the length of each module is predetermined and cannot be changed after manufacturing
Solution Approach 1:
The invention extracts the electrode layers (bottom electrode layer and top electrode layer) from the web at the time of cutting, rather than having them pre-patterned. This allows the module length to be determined at cutting time rather than being fixed during manufacturing, providing flexibility while simplifying the manufacturing process.
Solution Approach 2:
The invention makes the module length dynamic by allowing it to be determined at the time of cutting rather than being fixed during manufacturing. The electrode layers are removed dynamically at cutting time, enabling flexible module length adjustment without requiring complex pre-patterning.
2Ease of manufacture
If printing techniques are used to provide separate bottom electrodes, then the process is flexible, but the available inks are too thick, too costly, and do not provide adequate barrier to oxygen and moisture ingress
Solution Approach 1:
The invention changes the parameters of the electrode layers by using vacuum deposition to create thin, continuous layers rather than relying on printed inks. This provides both ease of manufacture through continuous deposition and reliability through the formation of uniform, defect-free barrier layers that effectively prevent oxygen and moisture ingress.
Solution Approach 2:
The invention replaces the mechanical printing process with vacuum deposition. Instead of using thick printed inks that require drying and curing, the electrode layers are deposited as thin films in vacuum, eliminating the problems of ink thickness, cost, and inadequate barrier properties while maintaining manufacturing flexibility.
3Productivity
If sheets are cut from the roll between separate electrodes, then individual modules are formed, but specialized and expensive sheet-to-sheet lamination equipment is required for encapsulation
Solution Approach 1:
The invention merges the cutting and encapsulation operations into a single continuous process. By keeping the electrode layers attached to the web during cutting and then performing roll-to-roll encapsulation, the process eliminates the need for separate sheet handling and specialized sheet-to-sheet lamination equipment, thereby increasing productivity and reducing equipment complexity.
Solution Approach 2:
The invention performs preliminary encapsulation of the entire web before cutting into individual sheets. This preliminary action allows standard roll-to-roll lamination equipment to be used instead of requiring specialized sheet-to-sheet equipment, simplifying the overall process and improving productivity.
4Device complexity
If a continuous top electrode layer is provided along the whole length of the web, then the structure is simpler, but cutting the web requires removing electrode material which complicates the process
Solution Approach 1:
The invention extracts the continuous electrode layers from the web at the time of cutting rather than trying to cut through them. This maintains the simplicity of the continuous electrode structure during manufacturing while simplifying the cutting process, as the electrodes are removed along with the substrate material rather than requiring precise cutting through the conductive layers.
Data Source
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AI summary
A flexible, thin film electronic device comprising a module (200) cut from a web provided with one or more cells (10) along substantially the whole of its length wherein the cells comprise a first electrode layer (13), a second electrode layer (17) and one or more active layers (15) provided between the electrode layers (13,17) characterised in that the module (200) includes one or more edge portions (22) wherein an edge of the first electrode layer (13) and an edge of the second electrode layer (17) are each substantially coincident with an edge of the web.