Photovoltaic Module Single-Step Lamination Using Low-Cure Prepregs
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Solution Overview
Problem
The manufacturing process of light, rigid, and resistant photovoltaic modules is inefficient due to the need for pre-manufactured support structures and layers, requiring multiple assembly steps and adhesive layers, which increases operational time and costs.
Innovation Solution
A method involving a stack of pre-impregnated materials with selected curing temperatures below the rolling temperature, allowing for a single-step lamination process where the support structure and layers are formed simultaneously, eliminating the need for pre-lamination and adhesive layers, and integrating components like junction boxes and frames during the rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support structure and layers are pre-manufactured by lamination before assembly, then the mechanical strength and structural integrity are ensured, but the manufacturing time and operational costs increase due to multiple assembly steps
Solution Approach 1:
The patent merges the support structure and encapsulation layers into a single integrated component manufactured in one lamination step. The prepreg materials are layered with the support structure between them, then simultaneously laminated and cured together, eliminating the need for separate pre-manufacturing and assembly operations while maintaining mechanical strength.
Solution Approach 2:
The support structure is prepared in advance by impregnating it with resin (prepreg) before lamination, but the actual structural formation and bonding occurs during the single lamination step. This preliminary impregnation allows the support structure to be ready for integration without requiring separate pre-manufacturing of the entire assembly.
2Reliability
If multiple adhesive layers are used to link elements of the photovoltaic module, then the structural reliability is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the support structure and encapsulation layers into a single integrated component, eliminating the need for separate adhesive layers to bond them. The prepreg materials themselves serve as both structural support and bonding medium, reducing manufacturing complexity while maintaining structural reliability.
Solution Approach 2:
The prepreg materials perform multiple functions simultaneously: they provide structural support, electrical insulation, mechanical bonding, and environmental protection. This multi-functionality eliminates the need for separate adhesive layers and reduces overall manufacturing complexity.
3Productivity
If the curing temperatures of prepreg materials are kept below the rolling temperature, then a single-step lamination process is enabled, but the selection of suitable materials becomes more constrained
Solution Approach 1:
The patent changes the temperature parameter by selecting prepreg materials with low curing temperatures (below the rolling temperature). This parameter change enables the curing process to occur during the rolling/lamination step itself, allowing single-step manufacturing while maintaining material compatibility.
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 reduces manufacturing time and costs by integrating multiple components in a single step, resulting in a lightweight, mechanically robust photovoltaic module that meets IEC standards for mechanical resistance while maintaining high electrical performance.
Implementation Method 1
a first pre-impregnated material having a first curing temperature, a second pre-impregnated material having a second curing temperature, a third pre-impregnated material having a third curing temperature, the first, second and third prepreg materials being selected such that, for a curing time, the first, second and third curing temperatures are below a rolling temperature
Data Source
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AI summary
A method for manufacturing a photovoltaic module involves the steps of: a) providing a stack (1) successively comprising: - a first layer (10) that is transparent in the visible range and is made of a first prepreg having a first curing/softening temperature; - an assembly of photovoltaic cells (2) encapsulated in an encapsulation material (3); - a second layer (11) made of a second prepreg having a second curing/softening temperature; - a support structure (4) designed to support the assembly of photovoltaic cells (2); - a third layer (12) made of a third prepreg having a third curing/softening temperature, the first, second and third prepregs being selected such that during a curing/softening period, the first, second and third curing/softening temperatures are lower than a laminating temperature; b) laminating the stack (1) at the laminating temperature during a lamination period that is at least as long as the curing/softening time, the support structure (4) and the second and third layers (11, 12) not having been laminated prior to step b).