Moldable Photovoltaic Module With Thermoformable Encapsulant
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Solution Overview
Problem
Current photovoltaic systems are not competitive with fossil-fuel generated electricity due to high costs, necessitating a reduction in photovoltaic module costs and assembly costs while maintaining functionality, which can be achieved by reducing the size of solar cells and using flexible, moldable materials to create cost-effective and flexible solar cell modules.
Innovation Solution
A moldable solar cell module comprising small, thin solar cells with electrical contacts attached to a flexible substrate and encapsulated in a thermoplastic fill material, allowing the module to be molded into three-dimensional shapes for various applications, such as electronic devices and outdoor gear, while maintaining photovoltaic functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If small, thin solar cells are used to reduce material costs, then photovoltaic material cost is reduced, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The patent uses composite materials by combining thin solar cells with a flexible substrate and encapsulant material. The solar cells are mounted on a flexible substrate that provides mechanical support, and the encapsulant material protects the cells while maintaining flexibility. This composite structure allows the use of thin, cost-effective solar cells without sacrificing mechanical strength.
Solution Approach 2:
The patent employs flexible substrates and thin film encapsulants to support the solar cells. The flexible substrate acts as a carrying structure that distributes mechanical stress, while the thin film encapsulant protects the solar cells from environmental damage. This approach enables the use of thin solar cells while maintaining structural integrity through the flexible support system.
2Stability of the object's composition
If traditional rigid photovoltaic modules are used, then structural stability is maintained, but adaptability to different surfaces and applications deteriorates
Solution Approach 1:
The patent transitions from rigid to flexible photovoltaic modules, enabling dynamic adaptation to various surfaces and applications. The flexible substrate and encapsulant material allow the module to conform to curved surfaces, irregular shapes, and different mounting configurations while maintaining structural integrity through the flexible support system.
Solution Approach 2:
The flexible photovoltaic module design provides universal applicability across multiple surfaces and applications. The module can be adapted to curved surfaces, flat surfaces, portable devices, building-integrated applications, and outdoor gear, making it a multi-functional solution that replaces traditional rigid modules in diverse contexts.
3Adaptability or versatility
If solar cells are attached to a flexible substrate, then flexibility and moldability are improved, but electrical contact reliability may deteriorate
Solution Approach 1:
The patent uses flexible substrates and thin film conductors to create electrical contacts that maintain reliability while enabling flexibility. The flexible substrate provides mechanical support and electrical connectivity, while the encapsulant material protects the electrical contacts from environmental damage and mechanical stress, ensuring reliable electrical performance in flexible configurations.
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 solution enables the creation of flexible solar cell modules that can be molded into desired shapes, reducing production costs and enhancing functionality, thus making photovoltaic systems more competitive with fossil-fuel generated electricity.
Implementation Method 1
The moldable fill material may be a material such as ethylene-vinyl-acetate (EVA) that has thermoplastic properties so that the solar cell module can be molded into a three-dimensional shape by heating and cooling the module.
Implementation Method 2
The solar cell module may then be cooled to retain the desired three-dimensional shape.
Data Source
AI summary
A moldable photovoltaic module is provided. The module includes a flexible polymeric flex-circuit substrate having an electrically conductive printed wiring pattern and solder pads defined on it. Small photovoltaic cells are affixed to the flex-circuit substrate by back-surface contacts in electrical contact with the solder pads. At least one thermoformable polymeric film is joined to the flex-circuit substrate. Each said solder pad comprises a solder composition that, after an initial melt, has a melting point that lies above at least a portion of the temperature range for thermoforming the polymeric film.