Folded PV Lamella Assembly for Large-Area Solar Module Lamination
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Solution Overview
Problem
Current vacuum lamination processes for manufacturing large-area solar modules are limited by the size of commercially available vacuum laminators, making it difficult to produce modules larger than 10 m² without custom and costly equipment, and requiring post-lamination steps that increase production complexity and risk.
Innovation Solution
A method for manufacturing large-area solar modules using a continuous additive lamination process, where individual PV lamellas are bonded together using a foldable material and encapsulant materials within a vacuum laminator, allowing for modules of any desired length without size limitations and reducing the need for post-lamination steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a vacuum laminator is used to manufacture large-area solar modules, then the photovoltaic active devices are protected from degradation and high system voltages, but the module size is limited by the dimensions of commercially available vacuum laminators (typically <10 m²)
Solution Approach 1:
The solar module is divided into multiple individual photovoltaic active panels (lamellas) that can be manufactured separately using standard vacuum laminators. These panels are then connected in series or parallel to form a large-area module, allowing the final product to exceed the size limitations of individual laminators while maintaining manufacturing simplicity and flexibility.
Solution Approach 2:
The invention transitions from manufacturing a single large-area module in one step to a multi-step process where smaller panels are created first and then assembled into a larger configuration. This dimensional approach allows the final module area to be much larger than what a single vacuum lamination process can produce, effectively adding an assembly dimension to the manufacturing process.
2Area of stationary object
If custom-sized large vacuum laminators are designed to produce modules larger than 10 m², then the module size limitation is overcome, but the equipment becomes extremely costly and difficult to ship to customers
Solution Approach 1:
Instead of using one large custom vacuum lamination machine, the system segments the manufacturing into multiple standard-sized vacuum laminators that process individual panels. These panels are then assembled into large-area modules, avoiding the need for expensive, logistically complex custom equipment while achieving the same large-area result.
Solution Approach 2:
The individual photovoltaic panels serve as intermediary components that bridge the gap between standard vacuum lamination capabilities and large-area module requirements. These intermediate panels are easily manufactured with conventional equipment and then assembled into the final large-area configuration, eliminating the need for specialized large-scale lamination equipment.
3Area of stationary object
If post-lamination steps are used to connect individual panels into large-area modules, then the desired large area is achieved, but production complexity and risk increase
Solution Approach 1:
The invention merges the electrical connections and mechanical assembly into a unified process where conductive adhesive is applied during the lamination process itself rather than as a separate post-lamination step. This integration reduces the number of discrete steps, lowers production complexity, and minimizes handling risks while achieving both electrical functionality and structural assembly.
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 method enables the production of lightweight, glass-free, and flexible solar modules of any length, reducing manufacturing time and costs, and integrating mechanical and electrical elements directly into the lamination process for enhanced functionality.
Implementation Method 1
A first encapsulant material is configured to bond the PV cell to the back sheet, and a second encapsulant material is configured to bond the PV cell to the front sheet
Implementation Method 2
A first edge of the foldable material is sandwiched between the first and second encapsulant materials of the first lamella and a second edge of the foldable material is sandwiched between corresponding first and second encapsulant materials of a second lamella
Data Source
AI summary
A photovoltaic, PV, module includes plural PV sections, each PV section including plural lamellas. A first lamella of the plural lamellas includes a back sheet, a first encapsulant material, a PV cell, a foldable material, a second encapsulant material, and a front sheet. The first encapsulant material bonds the PV cell to the back sheet, and the second encapsulant material bonds the PV cell to the front sheet. A first edge of the foldable material is sandwiched between the first and second encapsulant materials of the first lamella and a second edge of the foldable material is sandwiched between corresponding first and second encapsulant materials of a second lamella of the plural lamellas.