IBC Solar Cell Protective Layer for Scratch-Free Packaging

Solution Overview

Problem

The light-receiving surface of interdigitated back contact (IBC) solar cells is prone to scratching during storage and transportation due to direct contact with adjacent cells, reducing photoelectric conversion performance, and the use of separator paper is cumbersome and costly.

Innovation Solution

A protective layer with high light transmittance and heat resistance is applied to the light-receiving surface of the solar cell, bonded via a bonding layer, eliminating the need for separator paper and preventing scratches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If separator paper is placed between adjacent solar cells during storage and transportation, then the light-receiving surface is protected from scratching, but the production process becomes cumbersome and failure rate increases

Engineering Contradiction:

Improvescratch protectionVSAvoidpackaging complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The protective layer is integrated directly onto the light-receiving surface of the solar cell, merging the protection function with the cell structure itself. This eliminates the need for separate separator paper packaging, reducing packaging complexity while maintaining scratch protection during storage and transportation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective layer is applied in advance to the light-receiving surface before storage and transportation. This preliminary protective action ensures the surface is already protected when cells are stacked, eliminating the need for additional separator paper during packaging.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If separator paper is used between solar cells, then scratching is prevented, but production efficiency decreases and costs increase

Engineering Contradiction:

Improvescratch protectionVSAvoidproduction efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The protective layer is integrated directly onto the light-receiving surface of the solar cell, merging the protection function with the cell structure itself. This eliminates the need for separate separator paper packaging, reducing packaging complexity while maintaining scratch protection during storage and transportation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solar cell structure itself provides the protection function through the integrated protective layer, rather than requiring external separator paper. The cell is self-protecting during storage and transportation, eliminating the need for additional protective materials and simplifying the production process.

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If separator paper is placed between solar cells, then light-receiving surface protection is improved, but material consumption increases and costs rise

Engineering Contradiction:

Improvescratch protectionVSAvoidseparator paper consumption

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The protective layer is integrated directly onto the light-receiving surface of the solar cell, merging the protection function with the cell structure itself. This eliminates the need for separate separator paper packaging, reducing packaging complexity while maintaining scratch protection during storage and transportation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of using disposable separator paper that is consumed during packaging, the protective layer is a permanent, reusable integral part of the solar cell structure. This eliminates continuous material consumption and associated costs.

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 protective layer effectively prevents scratches and enhances production efficiency by integrating seamlessly with the lamination process, reducing failure rates and costs.

Implementation Method 1

Light transmittance of the protective layer being greater than a light transmittance threshold

Methodology Applied

Scientific EffectLight transmittance: Absorption (EM radiation)

Implementation Method 2

a first surface of the protective layer is bonded to a first surface of the bonding layer, and a second surface of the bonding layer is bonded to the light-receiving surface of the solar cell

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20250351618A1Solar cell, photovoltaic module, and method for packaging solar cell

Publication Date: 2025.11.13 LONGI SOLAR TECHNOLOGY (TAIZHOU) CO LTD

AI summary

The present disclosure provides a solar cell, a photovoltaic module, and a method for packaging a solar cell. An example method of packaging a solar cell includes arranging a protective layer on a light-receiving surface of the solar cell. A light transmittance of the protective layer is greater than a light transmittance threshold, and a heat-resistant temperature of the protective layer is greater than or equal to a heat-resistant temperature threshold.