Photovoltaic Module Encapsulation with Fast-Curing Alignment Structures
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Solution Overview
Problem
Existing photovoltaic modules face issues with glue separation between packaging structures and solar cells, leading to poor stability and increased labor intensity during encapsulation, which affects encapsulating efficiency and module stability.
Innovation Solution
A photovoltaic module design featuring a first and second encapsulating adhesive film with aligned holes and filling structures made of fast-curing material, along with protrusion structures, to facilitate rapid positioning and prevent relative slip during encapsulation, enhancing stability and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional encapsulating adhesive films are used without alignment features, then the encapsulation process is simpler, but the cell strings cannot be rapidly positioned and relative slip occurs during encapsulation
Solution Approach 1:
The encapsulating adhesive film is pre-formed with protrusion structures and aligned holes before the encapsulation process. These protrusion structures extend toward the cell strings and provide preliminary positioning guidance, enabling rapid and accurate alignment during encapsulation without adding complex positioning devices.
Solution Approach 2:
The protrusion structures on the encapsulating adhesive film act as intermediary elements between the adhesive film and the cell strings. These protrusions provide mechanical engagement points that facilitate positioning and prevent relative slip, serving as a mediating mechanism that simplifies the overall encapsulation process.
2Productivity
If slow-curing adhesive materials are used, then the adhesive film has sufficient working time for positioning, but the encapsulation process becomes time-consuming and labor-intensive
Solution Approach 1:
The protrusion structures and aligned holes are pre-formed on the encapsulating adhesive film before the encapsulation process begins. This preliminary preparation enables rapid positioning of cell strings during encapsulation, significantly reducing the time required for alignment and improving overall encapsulation efficiency without requiring slow-curing materials.
3Reliability
If the encapsulating adhesive film lacks alignment features, then the film structure is simpler, but glue separation occurs between the packaging structure and solar cells
Solution Approach 1:
The protrusion structures and aligned holes are pre-formed on the encapsulating adhesive film to provide positioning guidance before encapsulation. This preliminary alignment ensures that the cell strings are correctly positioned relative to the packaging structure, preventing glue separation and improving the long-term stability and reliability of the photovoltaic module.
Solution Approach 2:
The protrusion structures serve as intermediary mechanical engagement points between the encapsulating adhesive film and the cell strings. These protrusions ensure proper positioning and prevent relative movement during encapsulation, thereby preventing glue separation and enhancing the reliability of the bonding interface.
4Manufacturing precision
If manual positioning methods are used without alignment features, then the equipment is simpler, but labor intensity increases and positioning accuracy decreases
Solution Approach 1:
The protrusion structures and aligned holes are pre-formed on the encapsulating adhesive film to provide built-in alignment features. These features guide the positioning of cell strings during encapsulation, significantly improving positioning accuracy without requiring complex external positioning equipment or manual adjustment mechanisms.
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 design ensures stable adhesion and positioning of cell strings, preventing slip and improving the yield and service life of photovoltaic modules by utilizing fast-curing materials and protrusions to solidify before the films fully set, thereby enhancing encapsulation efficiency.
Implementation Method 1
a ratio of a thickness of the at least one filling structure to a sum of a depth of the at least one first hole and a depth of the at least one second hole is 1:0.8 to 1:1.2; wherein the at least one filling structure includes a material having a crosslinking curing speed that is faster than a crosslinking curing speed of a material in the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material in the second encapsulating adhesive film
Data Source
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AI summary
The disclosure relates to the field of solar energy, and more particularly to a photovoltaic module and a method for manufacturing the photovoltaic module. The photovoltaic module includes a plurality of cell strings; a first encapsulating adhesive film and a second encapsulating adhesive film that are stacked, where there is a gap between the first encapsulating adhesive film and the second encapsulating adhesive film; where the photovoltaic module has a central region and a peripheral region surrounding the central region, and the plurality of cell strings are disposed in the central region, where the first encapsulating adhesive film defines at least one first hole in the peripheral region, and the second encapsulating adhesive film defines at least one second hole in the peripheral region, and each first hole is aligned with a corresponding second hole and the at least one first hole and the at least one second hole include one or more through holes; and at least one filling structure each being filled in a respective first hole and a respective second hole, where the at least one filling structure includes a material having a crosslinking curing speed that is faster than a crosslinking curing speed of a material in the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material in the second encapsulating adhesive film.