Photovoltaic Module Encapsulation Structure for Edge Delamination
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Solution Overview
Problem
Current photovoltaic modules are prone to issues such as bubbles and delamination due to weak bonding strength in the edge area of the encapsulation film, which affects their reliability and service life.
Innovation Solution
The proposed photovoltaic module design includes a first and second adhesive film with specific material configurations and overlapping areas to ensure same-material contact interfaces during lamination, enhancing bonding strength and reducing the probability of delamination, with the second sub-adhesive film made of POE to minimize Potential Induced Degradation (PID) effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer adhesive film is used in current photovoltaic modules, then the manufacturing process is simple, but the bonding strength in the edge area is weak leading to bubbles and delamination
Solution Approach 1:
The adhesive film is segmented into multiple sub-adhesive films (first sub-adhesive film and second sub-adhesive film) with different materials and positions. The first sub-adhesive film is located at the edge area with width of 10-70mm to provide strong bonding, while the second sub-adhesive film covers the central area and part of the edge area. This segmentation allows each layer to perform its specific function, resolving the contradiction between bonding strength and structural complexity.
Solution Approach 2:
Different areas of the adhesive film structure are given different material properties: the first sub-adhesive film at the edge area uses material matching the cover plate for strong bonding, while the second sub-adhesive film facing the cell string uses POE material for anti-PID performance. This local differentiation of material quality optimizes both bonding strength and reliability without excessive complexity.
2Reliability
If the adhesive film material is not optimized, then the manufacturing cost is low, but delamination and bubbles occur during use reducing reliability
Solution Approach 1:
The patent applies different material qualities to different locations: the first sub-adhesive film at the edge uses material matching the cover plate (EVA, PVB, or POE) for bonding strength, while the second sub-adhesive film uses POE for anti-PID performance. This localized material optimization improves reliability without making the entire structure complex.
Solution Approach 2:
The adhesive film uses a composite structure of different materials (EVA/PVB/POE combination) where each material serves its optimal function. The POE material in the second sub-adhesive film provides anti-PID performance, while the first sub-adhesive film material matches the cover plate for bonding. This composite approach enhances reliability while maintaining manufacturing feasibility.
3Duration of action of stationary object
If the edge area bonding is not enhanced, then the structure is simple, but delamination occurs at the edge reducing service life
Solution Approach 1:
The adhesive film is divided into functional segments with the first sub-adhesive film specifically positioned at the edge area (width 10-70mm) to prevent delamination and extend service life. This segmentation targets the critical edge area without making the entire structure unnecessarily complex.
Solution Approach 2:
The first sub-adhesive film is pre-positioned at the edge area before lamination to ensure strong bonding from the beginning. This preliminary placement of bonding-enhancing material at the vulnerable edge area prevents future delamination and extends module service life.
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 design significantly improves the bonding strength and reliability of the encapsulation film, reducing the likelihood of delamination and PID effects, thereby enhancing the overall performance and stability of the photovoltaic module.
Implementation Method 1
a first adhesive film, a cell string, a second adhesive film and a second cover plate which are sequentially stacked
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A photovoltaic module includes a first cover plate, a first adhesive film, a cell string, a second adhesive film and a second cover plate. The first cover plate has a first surface, facing the cell string and including a central area and an edge area surrounding the central area. The first adhesive film includes a first sub-adhesive film located on at least part of the edge area, and a second sub-adhesive film located on a surface of the first sub-adhesive film away from the first surface and having an orthographic projection on the first surface at least covering the central area and part of the edge area. Material of part of the first sub-adhesive film facing the cell string is the same as material of part of the second adhesive film facing the cell string, and material of part of the second sub-adhesive film facing the cell string is POE.