Low-Sodium Glass PV Module Package with Hermetic Edge Seal
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Solution Overview
Problem
Photovoltaic modules experience continuous degradation due to ion migration, water ingress, and environmental moisture, leading to reduced efficiency and increased costs, with thin-film modules degrading more quickly than wafered modules.
Innovation Solution
The use of specialty glasses with reduced sodium content and a hermetic, fused glass/frit seal to minimize sodium migration and water ingress, combined with thin, flexible glass sheets for improved module reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional glass with high sodium content is used, then manufacturing cost is reduced, but sodium migration occurs leading to increased degradation and reduced reliability
Solution Approach 1:
The patent changes the chemical composition parameter of the glass by using low-sodium glass instead of conventional high-sodium glass. This parameter change prevents sodium migration into the photovoltaic cell, thereby improving module reliability and reducing degradation over time while accepting higher material costs.
Solution Approach 2:
The patent employs a composite sealing structure combining glass frit and metal alloy in the edge seal. This composite material approach creates a hermetic seal that prevents moisture and sodium ingress, improving reliability through enhanced barrier properties despite increased manufacturing complexity.
2Reliability
If conventional edge seals are used, then manufacturing simplicity is maintained, but moisture resistance is insufficient leading to water ingress and degradation
Solution Approach 1:
The patent uses a composite edge seal consisting of glass frit and metal alloy materials. The glass frit provides chemical bonding and hermetic sealing, while the metal alloy provides structural integrity. This composite approach achieves superior moisture resistance compared to conventional single-material seals.
Solution Approach 2:
The glass frit acts as an intermediary material between the metal alloy frame and the glass sheets. It provides a hermetic barrier that prevents moisture penetration while accommodating thermal expansion differences between materials, thereby enhancing moisture resistance.
3Strength
If thick glass sheets are used, then structural strength is improved, but module weight increases and active area efficiency decreases
Solution Approach 1:
The patent changes the thickness parameter of the glass sheets from conventional thick glass to thin glass sheets (e.g., 1.6mm or less). This parameter reduction decreases module weight and increases active area efficiency while maintaining structural strength through the use of low-sodium glass and improved edge sealing.
4Weight of moving object
If thin glass sheets are used, then module weight is reduced and active area efficiency is improved, but structural strength and durability are compromised
Solution Approach 1:
The patent uses a composite edge seal structure with glass frit and metal alloy that provides enhanced structural support for thin glass sheets. This composite sealing system distributes mechanical stresses and prevents glass breakage, enabling the use of thin glass while maintaining structural strength.
Solution Approach 2:
The glass frit in the edge seal acts as an intermediary that bonds the thin glass sheets to the metal frame, providing mechanical support and stress distribution. This intermediary structure enables thin glass to achieve sufficient structural strength for module applications.
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
This approach significantly reduces degradation rates, increasing energy output by up to 30% over the module's lifetime and enhancing reliability, while also reducing module weight and increasing active area efficiency.
Implementation Method 1
a hermetic, fused glass/frit seal to minimize sodium migration and water ingress
Implementation Method 2
Photovoltaic modules are used to convert sunlight into electricity
Data Source
Figure 1A~2
Figure 3~4B
Figure 5A~6
AI summary
A silicon wafer-based photovoltaic module is described, which includes a first outer protective layer and a second outer protective layer, wherein both outer protective layers comprise a low- or no-sodium glass or low- or no-alkali compositions. The photovoltaic modules show resistance to water ingress, no or reduced potential-induced sodium ion drift, and reduced potential induced degradation.