Stainless Steel Mesh Flexible Solar Module Packaging Against Tearing
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Solution Overview
Problem
Flexible solar cell modules face issues such as delamination, deformation, and tearing when exposed to high temperature and humidity environments, leading to performance decline and quality affect, due to insufficient strength and susceptibility to moisture and oxidation.
Innovation Solution
A flexible assembly with a stainless steel mesh packaging structure is introduced, featuring a stainless steel mesh layered around the solar cell string, providing corrosion resistance, high temperature resistance, and enhanced strength, using materials like SUS302 and ethyl tetra fluoro ethylene (ETFE) with hot melt adhesives like EVA and Surlyn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible solar cell module uses a flexible back plate and front plate with hot melt adhesive, then the assembly achieves flexibility and ease of installation, but the structure suffers from insufficient strength leading to tearing and delamination in harsh environments
Solution Approach 1:
The patent introduces a stainless steel mesh layer embedded within the flexible assembly structure, creating a composite material system that combines the flexibility of polymer materials with the high strength and tear resistance of metal mesh. This composite structure maintains the flexible characteristics needed for installation while dramatically improving mechanical strength and resistance to tearing in harsh environments
2Adaptability or versatility
If the flexible solar cell module is exposed to high temperature and humidity environments, then the module can be used in diverse application scenarios, but the product experiences oxidation, yellowing, and de-welding of welding strips
Solution Approach 1:
The stainless steel mesh provides an inert physical barrier that protects the internal components (welding strips, adhesive layers, solar cells) from direct contact with corrosive environmental factors such as moisture and oxygen. This passive protection prevents oxidation and chemical degradation while maintaining the module's ability to function in diverse environmental conditions
Solution Approach 2:
The combination of stainless steel mesh with flexible polymer materials creates a composite structure that simultaneously provides environmental protection and maintains flexibility. The stainless steel component resists corrosion and oxidation while the polymer layers provide weather resistance and structural integrity
3Ease of operation
If metal buckles are embedded in the flexible front back plate for suspension purposes, then the assembly gains mounting capability, but the insufficient strength of the flexible plate causes tearing at the embedding positions
Solution Approach 1:
The stainless steel mesh embedded within the flexible plate provides internal reinforcement at critical locations. When metal buckles are embedded for mounting purposes, the stainless steel mesh distributes and bears the localized stresses, preventing tearing while maintaining the flexibility needed for buckle integration and mounting operations
Data Source
AI summary
A flexible assembly with a stainless steel mesh packaging structure includes a flexible back plate, a first hot melt adhesive, a solar cell string, a stainless steel mesh, a second hot melt adhesive, and a flexible front plate. The flexible back plate and the flexible front plate are respectively arranged on the outer surface of the first hot melt adhesive and the outer surface of the second hot melt adhesive, and the solar cell string and the stainless steel mesh are arranged between the first hot melt adhesive and the second hot melt adhesive. The stainless steel mesh is arranged at partial or all positions around the outer edge of the solar cell string and is continuously distributed or separately distributed. The stainless steel mesh is arranged around the solar cell string to further strengthen the strength of the flexible assembly and improve the tearing resistance of the flexible assembly.