Photovoltaic Strip Fabrication Using Elastomer Encapsulation
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Solution Overview
Problem
Conventional solar panels are costly, difficult to manufacture on a large scale, and have design variations that make them challenging to adapt for common use, leading to high costs and limited availability of photovoltaic silicon materials.
Innovation Solution
A method of physically separating semiconductor wafers into discrete photovoltaic strips based on their optical, thermal, or electrical characteristics, which are then tested and coupled with concentrating elements using an elastomer encapsulant, reducing the amount of silicon required and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional silicon bearing wafer materials are used for solar panels, then photovoltaic cells can be manufactured, but the cost is high and manufacturing efficiency on large scale is difficult
Solution Approach 1:
The patent segments the solar panel structure by separating the photovoltaic function from the substrate. Instead of using conventional silicon wafers, the invention uses flexible substrates with deposited photovoltaic layers, allowing the photovoltaic function to be divided into thin, flexible layers that can be manufactured at scale using deposition techniques rather than traditional wafer processing
Solution Approach 2:
The patent replaces expensive, difficult-to-manufacture silicon wafers with cheaper, easily manufacturable flexible substrates and deposited photovoltaic layers. This substitution enables large-scale production by using materials and processes that are more cost-effective and scalable, even if the individual components have shorter operational lifetimes
2Quantity of substance
If conventional silicon bearing wafer materials are used, then solar panels can be produced, but availability is scarce and difficult to purchase from limited sources
Solution Approach 1:
The patent creates a universal photovoltaic structure that can be manufactured using common deposition techniques on various flexible substrates. This universal approach eliminates dependence on specialized silicon wafer sources, allowing multiple manufacturers to produce photovoltaic panels using readily available materials and standard deposition equipment
Solution Approach 2:
By replacing scarce silicon wafers with abundant, cheap flexible substrates and deposited layers, the invention makes photovoltaic materials widely available from multiple sources rather than limited specialized suppliers, enabling broader access to manufacturing
3Reliability
If solar panels are made with conventional materials and methods, then they can function, but they are costly and cannot compete with direct electricity purchase
Solution Approach 1:
The patent uses inexpensive flexible substrates and deposition-based photovoltaic layers instead of costly silicon wafers. This substitution maintains sufficient photovoltaic functionality while dramatically reducing material costs, making the panels cost-competitive with conventional electricity sources
Solution Approach 2:
The invention changes the physical and material parameters of photovoltaic construction by using thin deposited layers on flexible substrates rather than thick rigid silicon wafers. This parameter change reduces material costs and manufacturing complexity while maintaining the essential photovoltaic function
4Adaptability or versatility
If conventional solar cell designs are used, then they can be manufactured, but design variations make adaptation difficult and increase costs
Solution Approach 1:
The patent creates a universal platform using flexible substrates and deposited photovoltaic layers that can accommodate various designs and configurations. This universal structure allows easy adaptation to different applications by changing the deposition patterns or substrate properties without requiring entirely different manufacturing processes
Solution Approach 2:
The flexible substrate and deposited layer structure allows dynamic adaptation of the photovoltaic design. The system can be easily reconfigured or modified by changing deposition parameters, layer structures, or substrate properties, enabling versatile adaptation to different design requirements
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 results in a more cost-effective and efficient solar cell production process that uses less silicon, is adaptable to different wafer designs, and can be easily integrated with existing technologies, offering a reliable and environmentally friendly energy solution.
Implementation Method 1
The elastomer encapsulant is provided between the photovoltaic strip and the concentrating element
Data Source
AI summary
A photovoltaic strip is physically separated from a semiconductor wafer utilizing physical sawing or other techniques. In accordance with one embodiment, a type of semiconductor wafer is first determined by interrogating the wafer to identify one or more of its optical, thermal, or electrical characteristics. This information regarding substrate type is then communicated to a separation apparatus, which then accomplishes precise physical separation of the substrate into discrete strips. Electrical performance of the strips may be tested prior to their incorporation into an assembled solar cell, where they are coupled to a concentrating element utilizing an elastomer encapsulant.