Photovoltaic Module Polyolefin Encapsulant Simplification
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Solution Overview
Problem
Existing photovoltaic solar systems face challenges in reducing complexity, weight, and cost, with encapsulants experiencing issues such as yellowing, stiffness, and high production costs, while also requiring additional components like thick backsheets for environmental protection and electrical insulation.
Innovation Solution
A photovoltaic laminate is constructed using a high volume resistivity polyolefin encapsulant, such as polyethylene or polypropylene, with a mono-layer film and simplified protective layer, eliminating the need for a multi-layer backsheet and enhancing manufacturing efficiency through surface treatments like corona and plasma treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional encapsulants are used in photovoltaic modules, then electrical insulation and environmental protection are provided, but the system complexity increases due to requiring additional thick backsheets, and manufacturing costs increase
Solution Approach 1:
The patent combines multiple functions (encapsulation, electrical insulation, environmental protection) into a single encapsulant layer with high volume resistivity, eliminating the need for separate thick backsheets and reducing system complexity while maintaining all necessary protective functions
Solution Approach 2:
The encapsulant is designed to perform multiple functions simultaneously: mechanical encapsulation of solar cells, electrical insulation through high volume resistivity, and environmental protection against moisture and contaminants, replacing what traditionally required multiple separate components
2Reliability
If traditional encapsulants are used in photovoltaic modules, then protective functions are maintained, but manufacturing costs increase and production efficiency decreases
Solution Approach 1:
The patent employs standard polyolefin materials (polyethylene, polypropylene) that are inexpensive and widely available, replacing costly specialized encapsulants while maintaining protective functions through optimized material selection and surface treatments
Solution Approach 2:
The patent changes the key parameter of volume resistivity to be sufficiently high for electrical insulation, allowing the use of common, low-cost polyolefin materials instead of expensive specialized encapsulants, thereby reducing manufacturing costs while maintaining protective functions
3Reliability
If high volume resistivity encapsulants are used, then electrical efficiency increases, but material selection becomes more restricted
Solution Approach 1:
The patent identifies and exploits the parameter of volume resistivity, selecting materials (polyethylene, polypropylene) that naturally exhibit sufficiently high values for electrical insulation, thereby achieving high electrical efficiency while working within common material constraints
Solution Approach 2:
The patent uses homogeneous polyolefin materials with consistent high volume resistivity properties, ensuring reliable electrical performance while simplifying material selection and processing compared to composite or multi-layer alternatives
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 material complexity and manufacturing costs, increases electrical efficiency, and maintains performance specifications by providing effective electrical insulation and environmental protection while inhibiting polarization and photon loss.
Implementation Method 1
surface treatments like corona and plasma treatment
Implementation Method 2
surface treatments like corona and plasma treatment
Data Source
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AI summary
A photovoltaic module is disclosed. The photovoltaic module has a first side directed toward the sun during normal operation and a second, lower side. The photovoltaic module comprises a perimeter frame and a photovoltaic laminate at least partially enclosed by and supported by the perimeter frame. The photovoltaic laminate comprises a transparent cover layer positioned toward the first side ofthe photovoltaic module, an upper encapsulant layer beneath and adhering to the cover layer, a plurality of photovoltaic solar cells beneath the upper encapsulant layer, the photovoltaic solar cells electrically interconnected, a lower encapsulant layer beneath the plurality of photovoltaic solar cells, the upper and lower encapsulant layers enclosing the plurality of photovoltaic solar cells, and a homogenous rear environmental protection layer, the rear environmental protection layer adhering to the lower encapsulant layer, the rear environmental protection layer exposed to the ambient environment on the second side of the photovoltaic module.