Grooved Functional Part for Overlapped Solar 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 improving yield and efficiency by positioning cells and distributing adhesive effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If module efficiency is improved by using overlapped regions in cell strings, then the module efficiency increases, but the risk of cracking and fragmenting during laminating increases, leading to lower yield
Solution Approach 1:
The patent applies beforehand cushioning by introducing grooves in the functional part (adhesive film or cover plate) at positions corresponding to the overlapped regions of cells. These grooves act as pre-designed stress relief structures that cushion the laminating pressure before it can cause cracking or fragmenting of the overlapped regions, thus preventing damage before it occurs while maintaining the high module efficiency design
2Strength
If the laminating pressure is increased to improve lamination quality, then the bonding strength improves, but the risk of cracking and fragmenting of overlapped regions increases
Solution Approach 1:
The patent applies segmentation by dividing the functional part into regions with grooves and regions without grooves. The grooves are specifically positioned at the overlapped regions to segment the stress distribution during laminating. This allows the laminating pressure to be concentrated on non-overlapped regions while the overlapped regions are protected by the groove structures, enabling high bonding strength without cracking
Data Source
AI summary
The present disclosure provides a functional part, a photovoltaic module and a manufacturing method of 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 the cell string 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 towards the second surface. A location of each groove corresponds to a location of at least one overlapped region.