Photovoltaic Module Edge Protection for Frameless Moisture Sealing
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Solution Overview
Problem
Existing photovoltaic module manufacturing methods lack effective edge protection against mechanical impact and moisture penetration, often requiring complex sealing elements and additional frames, which complicate the manufacturing process and reduce efficiency.
Innovation Solution
A method involving a thin film solar module with side busbars, encapsulation foils, and a pressure mould to inject an edge protection mass, forming a circumferential edge protection that provides mechanical and moisture barrier without the need for additional frames, enhancing electrical isolation and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-component sealing element is used to protect edges, then edge protection against mechanical impact and moisture is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines the sealing function and edge protection function into a single integrated sealing element that runs continuously around the perimeter of the photovoltaic module. This eliminates the need for separate sealing components and complex multi-part assemblies, reducing device complexity while maintaining reliable edge protection against moisture and mechanical impact.
Solution Approach 2:
The sealing element serves multiple functions simultaneously: it provides moisture sealing, mechanical edge protection, and structural support. This multi-functional design eliminates the need for additional dedicated components, simplifying the overall device structure while achieving comprehensive edge protection.
2Reliability
If large adhesive volume or complex clamping elements are used to keep sealing elements in place, then sealing reliability is improved, but device complexity and manufacturing effort increase
Solution Approach 1:
The fixation function is merged into the sealing element itself through self-adhesive properties or integrated mechanical fixation features. This eliminates the need for separate clamping elements or excessive adhesive applications, reducing device complexity while ensuring reliable fixation of the sealing element to the module structure.
3Strength
If frame structures are added for edge protection, then mechanical impact protection is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent extracts the essential edge protection function from complex frame structures and implements it through a simplified continuous sealing element. This sealing element provides the necessary mechanical protection and moisture sealing without requiring additional frame components, thereby reducing device complexity while maintaining strength and protection.
4Reliability
If complex sealing elements are used, then edge protection is improved, but manufacturing time and productivity decrease
Solution Approach 1:
The manufacturing process is segmented into standardized steps that facilitate efficient production of the continuous sealing element. The sealing element itself is designed as a single continuous component that can be applied in a streamlined manner, reducing manufacturing complexity and improving productivity compared to assembling multiple complex sealing components.
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 frameless photovoltaic modules with improved edge protection against mechanical damage and moisture penetration, increasing efficiency and reducing costs by eliminating the need for additional frames and complex sealing elements.
Implementation Method 1
placing a pressure mould over the edge of the substrate stack, injecting an edge protection mass into the pressure mould, moving the pressure mould along the edges of the substrate stack to form a circumferential edge protection
Data Source
AI summary
A method for manufacturing a photovoltaic module with edge protection comprising: a) providing a transparent module substrate comprising a thin film solar module on a first surface of the transparent module substrate, b) applying at least two side busbars to the thin film solar module, c) placing a first encapsulation foil onto the thin film solar module, d) placing a transparent back substrate onto the first encapsulation foil, e) placing a second encapsulation foil onto a second surface of the transparent module substrate, f) placing a transparent front substrate onto the second encapsulation foil, g) laminating a substrate stack, h) placing a pressure mould over the edge of the substrate stack, i) injecting an edge protection mass into the pressure mould, and j) moving the pressure mould along the edges of the substrate stack to form a circumferential edge protection, as well as a photovoltaic module comprising an edge protection.