Grooved Functional Part for Overlapped PV Cell Lamination
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Solution Overview
Problem
Photovoltaic module manufacturing faces challenges with low yield due to the risk of cracking and fragmenting of overlapped regions during the laminating process, which affects module efficiency and production costs.
Innovation Solution
Incorporating a functional part with grooves in the adhesive film and cover plates that buffer laminating pressure on overlapped regions, reducing the risk of cracking and fragmenting, and optimizing groove sizes and positions to improve yield and encapsulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If module efficiency is improved by optimizing cell arrangement and reducing gaps, then module efficiency increases, but the risk of cracking and fragmenting in overlapped regions increases, leading to lower yield
Solution Approach 1:
The patent introduces a buffer layer between the cover plate and the cell string that provides beforehand cushioning to the laminating pressure. This buffer layer absorbs and distributes the pressure before it reaches the overlapped regions of adjacent cells, preventing cracking and fragmenting while maintaining the tight cell arrangement needed for high module efficiency. The buffer layer acts as a protective intermediary that cushions the cells from direct pressure during lamination.
2Manufacturing precision
If laminating pressure is increased to improve encapsulation quality, then encapsulation quality improves, but the risk of cracking and fragmenting overlapped regions increases
Solution Approach 1:
The patent introduces a buffer layer as an intermediary between the cover plate and the cell string during lamination. This intermediary layer mediates the transmission of laminating pressure, allowing sufficient pressure to be applied for good encapsulation quality while preventing excessive concentration of force that would cause cracking in overlapped regions. The buffer layer translates the applied pressure into a distributed, controlled force that protects the cells.
3Strength
If cell overlap area is increased to improve mechanical strength and encapsulation, then mechanical strength improves, but the risk of cracking and fragmenting in overlapped regions increases during lamination
Solution Approach 1:
The buffer layer provides beforehand cushioning specifically targeted at the overlapped regions where cells are mechanically connected. By positioning the buffer layer to correspond with these overlapped regions, the patent ensures that the cushioning effect is applied precisely where the mechanical strength is most critical, protecting these vulnerable areas from pressure-induced cracking while maintaining the necessary overlap area for structural integrity.
Data Source
AI summary
The present disclosure provides a functional part, a photovoltaic module and a method of manufacturing photovoltaic modules. The functional part is configured to form a photovoltaic module with a cell string that includes a plurality of cells. Adjacent cells of share an overlapped region. The functional part has a first surface facing the cell string and a second surface opposite to the first surface. The functional part includes at least one groove extending from the first surface toward the second surface. A location of each groove corresponds to a location of at least one overlapped region.