Photovoltaic Module Encapsulation for Free Acid Dissipation
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Solution Overview
Problem
Photovoltaic modules face reliability issues due to the production of free acids like acetic acid from ethylene-vinyl acetate (EVA) fillers, which can corrode solar cell electrodes and joints, leading to reduced performance and maintainability over time.
Innovation Solution
Incorporating a weather-resistant resin front protective layer that is moisture-permeable and watertight, allowing free acids to dissipate externally, while using acid-modified resins like EVA or PVB in the filler to manage acid generation, and employing microthrough-holes or protective members to further protect the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If EVA filler is used to cover solar cells, then the solar cells are protected and held in place, but free acid is generated under heat and moisture causing corrosion of electrodes and joints
Solution Approach 1:
The patent extracts and removes the harmful free acid substance from the system by providing escape paths (through-holes) that allow the free acid to leave the encapsulation structure and dissipate externally, preventing its accumulation and corrosive effects on electrodes and joints
Solution Approach 2:
The patent converts the harmful free acid byproduct into a beneficial flow by directing it through controlled pathways (through-holes in front and back protective layers) to escape the system, transforming the corrosion risk into a controlled dissipation process that actually protects the solar cells
2Object-affected harmful factors
If a watertight front protective layer is used, then moisture protection is improved, but free acid cannot dissipate externally
Solution Approach 1:
The patent employs porous or permeable protective layers with controlled through-holes that allow selective passage: the structure maintains overall moisture barrier functionality while creating specific channels for free acid vapor or liquid to escape through, achieving both moisture protection and acid dissipation simultaneously
Solution Approach 2:
The through-holes act as intermediary pathways that mediate between the conflicting requirements of moisture barrier and acid dissipation, allowing the system to satisfy both conditions by providing a controlled interface for selective物质 transfer
3Duration of action of stationary object
If the front protective layer is made weather-resistant, then long-term durability is improved, but free acid corrosion of electrodes still occurs
Solution Approach 1:
The patent extracts the harmful free acid from the encapsulation environment before it can reach and corrode the electrodes and joints, using through-holes to provide escape paths that remove the corrosive agent while maintaining the weather-resistant barrier function
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 solution enhances the long-term reliability of photovoltaic modules by preventing corrosion of electrodes and joints, maintaining high photoelectric conversion efficiency and extending the module's operational lifespan.
Implementation Method 1
The filler includes a material with a chemical structure to generate a free acid
Implementation Method 2
The front protective layer is moisture-permeable and watertight, allowing free acids to dissipate externally
Data Source
AI summary
A photovoltaic module includes a front protective layer, a back protective layer, a plurality of solar cells, and a filler. The front protective layer is transmissive to light and has a first surface and a second surface opposite to the first surface. The back protective layer faces the second surface. The plurality of solar cells are between the second surface and the back protective layer. The filler is between the front protective layer and the plurality of solar cells and covers the plurality of solar cells. The filler includes a material with a chemical structure to generate a free acid. The front protective layer includes a weather-resistance resin. At least a part of the first surface is exposed to a space external to the photovoltaic module.