Method for binding photovoltaic cells to a substrate impregnated with crosslinkable polymer material
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Solution Overview
Problem
The assembly of photovoltaic cells to a substrate for forming a photovoltaic module in space applications is complicated by the need for precise adjustment of silicone deposition patterns and the risk of gas bubbles trapped in the crosslinked silicone, which can lead to module degradation or explosion.
Innovation Solution
A method involving a flexible, impregnable substrate impregnated with a crosslinkable polymer material, where the photovoltaic cells are bonded to the substrate without requiring complex patterns, and the crosslinking process is facilitated through lamination, reducing gas bubble presence and enhancing the intimacy of the bond between cells and substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone is deposited on the substrate using a bonding robot according to a particular pattern, then the photovoltaic cells can be bonded to the substrate, but the process becomes complicated and gas bubbles can remain trapped in the crosslinked silicone
Solution Approach 1:
The substrate is pre-impregnated with crosslinkable polymer material before the photovoltaic cells are placed on it. This preliminary impregnation action eliminates the need for complex pattern deposition during assembly, as the material is already distributed throughout the substrate structure, ready to bond with the cells when they are placed and laminated.
Solution Approach 2:
The substrate is designed with porous or absorbent characteristics that allow it to take up and retain the crosslinkable polymer material throughout its structure. This porous structure enables uniform distribution of the bonding material without requiring precise pattern deposition, and facilitates complete impregnation that reduces trapped gas bubbles during the lamination process.
2Strength
If the substrate is impregnated with crosslinkable polymer material, then the bond between photovoltaic cells and substrate becomes more intimate and reliable, but the assembly process requires additional impregnation steps
Solution Approach 1:
The impregnation of the substrate with crosslinkable polymer material and the lamination bonding process are merged into an integrated manufacturing approach. The substrate is prepared with the polymer material beforehand, and during lamination, the same process that bonds the cells also completes the impregnation and initiates crosslinking, combining multiple functions into a single operational sequence.
Solution Approach 2:
The substrate structure itself serves the dual function of providing mechanical support and delivering the bonding material. By impregnating the substrate with crosslinkable polymer material, the substrate becomes self-sufficient in providing the bonding agent, eliminating the need for separate adhesive application steps and simplifying the overall manufacturing process.
3Reliability
If photovoltaic cells are assembled to a flexible substrate using adhesive deposited in patterns, then the cells can be bonded, but gas bubbles are favored and can cause module degradation or explosion
Solution Approach 1:
The substrate is designed with porous or absorbent characteristics that allow it to take up and retain the crosslinkable polymer material throughout its structure. This porous structure enables uniform distribution of the bonding material without requiring precise pattern deposition, and facilitates complete impregnation that reduces trapped gas bubbles during the lamination process.
Solution Approach 2:
The state of the bonding material is changed from a deposited adhesive layer to an impregnated polymer material that saturates the substrate structure. This parameter change in material distribution and physical state transforms the bonding approach from surface-level adhesive application to throughout-substrate impregnation, eliminating voids and gas bubble entrapment.
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 method simplifies the assembly process, reduces the risk of gas bubbles, and achieves a more intimate and reliable bond between photovoltaic cells and the substrate, ensuring the stability and reliability of the photovoltaic module for space deployment.
Implementation Method 1
the crosslinking of the crosslinkable polymer material
Implementation Method 2
impregnating portions of the substrate with a crosslinkable polymer material
Data Source
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AI summary
The method for binding photovoltaic cells (101) to a substrate (102), each photovoltaic cell (101) comprising a rear face (104) and a front face (105), comprises the steps of: providing the substrate (102), the substrate (102) being flexible and impregnable; impregnating portions (106) of the substrate (102) with a crosslinkable polymer material, the portions (106) being impregnated according to the thickness of the substrate (102), in order to bind the photovoltaic cells (101) to the substrate (102); bringing the rear faces (104) of the photovoltaic cells (101) into contact with the impregnated portions (106) of the substrate (102); crosslinking the crosslinkable polymer material.