Offset Electrode Lamination for Pinhole-Resistant Solar Modules
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Solution Overview
Problem
The existing methods for producing solar cell modules face challenges with pinholes in the active layer, leading to short circuits and reduced efficiency, particularly in low light conditions, where shunt currents are more critical.
Innovation Solution
A method for laminating solar cell modules using flexible substrates with offset electrodes, where the active layer is brought into physical contact with the electrodes after deposition, reducing the risk of pinholes and allowing for a more efficient solar cell module with increased active area coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode material is deposited to fill pinholes in the active layer, then short circuit risk is reduced, but manufacturing complexity increases and production efficiency decreases
Solution Approach 1:
The patent applies preliminary action by designing the electrode pattern in advance to inherently avoid pinhole formation. The electrodes are configured with sufficient spacing and optimized geometry before the active layer is deposited, eliminating the need for post-deposition pinhole filling operations. This preventive approach maintains high production efficiency while ensuring reliability.
2Reliability
If active layer is deposited before lamination, then pinholes may form causing short circuits, but depositing after lamination reduces manufacturing precision
Solution Approach 1:
The patent performs preliminary action by pre-configuring the electrode patterns with optimized spacing and geometry on the substrate before active layer deposition. This ensures that even if pinholes form during deposition, the electrodes are positioned to minimize short circuit risk, while maintaining manufacturing precision through controlled fabrication processes.
3Productivity
If roll-to-roll deposition is used for large area solar cells, then productivity increases, but pinhole formation risk increases leading to reduced reliability
Solution Approach 1:
The patent applies local quality by optimizing the electrode pattern characteristics in specific regions to address pinhole risks. The electrode spacing, width, and geometry are locally adjusted based on the deposition process characteristics and expected pinhole distribution, ensuring high reliability in high-productivity roll-to-roll manufacturing without compromising overall production speed.
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 minimizes the risk of short circuits, enhances module efficiency, and allows for the production of solar cell modules suitable for low light conditions, such as indoor energy harvesting, by ensuring the active layer and electrodes are securely connected without electrode material filling pinholes.
Implementation Method 1
laminating by means of heat and pressure said first and said second substrate portions together in a roll-to-roll process such that the active layer is brought into physical contact with the other one of said plurality first electrodes or said plurality of second electrodes
Data Source
AI summary
The present invention relates to a method for laminating solar cell modules comprising a plurality of solar cells electrically connected in series. The method comprises: providing a first and a second flexible substrate portion suitable for roll-to-roll deposition; providing a plurality of first electrodes on said first substrate portion and a plurality of second electrodes on said second substrate portion, wherein said plurality of first and second electrodes are provided as stripes spatially separated such that a plurality of gaps is formed; depositing a continuous or discontinuous active layer on said plurality of first electrodes or said plurality of second electrodes, where in said continuous or discontinuous active layer is an organic active layer; laminating by means of heat and pressure said first and said second substrate portions together in a roll-to-roll process such that the active layer is brought into physical contact with the other one of said plurality first electrodes or said plurality of second electrodes and such that the active layer is brought into electrical contact with said plurality of first electrodes and said plurality of second electrodes. The plurality of first electrodes is arranged off-set relative said plurality of second electrodes such that each of said plurality of gaps between said plurality of second electrodes are fully covered at least in one direction by respective one of said plurality of first electrodes. The present invention also relates to a solar cell module.