Foldable Solar Panel Interconnect Isolation for Repeated Bending
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Solution Overview
Problem
Conventional foldable solar panels face issues with the flexibility and durability of interconnection wires due to hardened adhesive films, leading to wire breakage and safety risks during repeated bending.
Innovation Solution
A foldable solar panel design that includes an isolation layer between the interconnection wire and the adhesive film layers, allowing the wire to move freely and preventing adhesion, thus enhancing wire flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive films are arranged at upper and lower sides of wires in folding region and subjected to high-temperature lamination process, then the adhesive films melt and wrap the wires, but the flexibility of the wires is reduced and wires break after repeated bending
Solution Approach 1:
A protective sleeve made of flexible insulating material is introduced as an intermediary between the wire and the adhesive film. The sleeve allows the adhesive to bond to the wire for electrical connection reliability while preventing the hardened adhesive from directly contacting and stiffening the wire, thus maintaining wire flexibility during repeated bending operations
Solution Approach 2:
The protective sleeve is constructed from flexible insulating material that can accommodate repeated bending without breaking. This flexible shell encapsulates the wire in the folding region, allowing the wire to move freely while still providing insulation and protecting against adhesive-induced stiffness
2Adaptability or versatility
If wires pass through folding region and are repeatedly bent, then the solar panel achieves foldability, but the wires are prone to breaking and causing open circuits
Solution Approach 1:
The protective sleeve acts as a flexible shell that encapsulates the wire throughout its length in the folding region. This flexible protection allows the wire to undergo repeated bending cycles required for solar panel foldability while preventing wire breakage and maintaining electrical connection reliability
Solution Approach 2:
The protective sleeve is installed on the wire before the lamination process, providing beforehand cushioning and protection. This pre-installation ensures that when the adhesive hardens and when repeated bending occurs, the wire is already protected, preventing breakage and maintaining durability
3Stability of the object's composition
If adhesive films are used to secure wires in folding region, then wire positioning is improved, but the hardened adhesive reduces wire flexibility and causes local heat
Solution Approach 1:
The protective sleeve serves as an intermediary that allows the adhesive to bond to the wire for stable positioning while preventing direct contact between the hardened adhesive and the wire. This separation eliminates the source of local heat generation that would otherwise occur at the adhesive-wire interface during repeated bending
Data Source
AI summary
A foldable solar panel includes a power generation layer (100) and two adhesive film layers (200) located on two opposite sides of the power generation layer (100). The power generation layer (100) includes a plurality of sub-power generation panels (110) arranged at intervals and an interconnection wire (120). A bent region (2000) is formed in a gap between two adjacent sub-power generation panels (110). The two adjacent sub-power generation panels (110) are electrically connected by the interconnect wire (120) passing through the bent region (2000). An isolation layer (300) is arranged between the interconnect wire (120) and the adhesive film layer (200).