Photovoltaic Module Encapsulation Structure to Prevent Film Slip
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Solution Overview
Problem
The encapsulating structure of solar photovoltaic modules is prone to glue separation, leading to poor stability and increased labor intensity during the encapsulating process, which affects the efficiency and longevity of the modules.
Innovation Solution
A photovoltaic module design featuring a first and second encapsulating adhesive film with strategically placed holes and filling structures made from materials with faster crosslinking curing speeds, along with protrusion structures to facilitate positioning and prevent relative slip, enhancing the module's stability and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive films are used for encapsulating solar cells, then the solar cells are sealed and protected, but glue separation occurs between the packaging structure and solar cells leading to poor stability
Solution Approach 1:
The filling structure is placed in advance within the adhesive films at positions corresponding to the solar cells. This preliminary placement creates mechanical interlocking points before the encapsulation process, preventing glue separation by establishing anchor points that maintain adhesion between the adhesive film and solar cells throughout operation.
Solution Approach 2:
The filling structure provides localized reinforcement at specific positions corresponding to the solar cells, rather than requiring uniform adhesion across the entire adhesive film. This local quality approach addresses adhesion problems at critical points where solar cells contact the adhesive film, preventing separation without compromising overall structural integrity.
2Productivity
If traditional encapsulating methods are used, then solar cells can be enclosed, but rapid positioning of solar cells cannot be achieved making the process time-consuming and labor-intensive
Solution Approach 1:
The filling structure is pre-positioned within the adhesive films before the solar cells are placed. This preliminary action creates predetermined positioning points that guide and accelerate the placement of solar cells, enabling rapid positioning without requiring complex alignment procedures or additional labor during the encapsulation process.
Solution Approach 2:
The filling structure provides self-aligning features that automatically guide the solar cells into correct positions during placement. The solar cells naturally settle onto the filling structures, which serve as mechanical guides, eliminating the need for external positioning tools or manual alignment adjustments and significantly reducing positioning time.
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 improves the positioning and adhesion between the adhesive films, preventing relative slip and enhancing the stability and service life of the photovoltaic modules by solidifying the filling structures before the films are fully shaped, thus improving the yield and stability of the modules.
Implementation Method 1
A crosslinking curing speed of a material forming the filling structure is faster than a crosslinking curing speed of a material forming the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material forming the second encapsulating adhesive film
Data Source
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AI summary
The disclosure relates to the field of solar energy, and more particularly to a photovoltaic module and a method for manufacturing the photovoltaic module. The photovoltaic module includes a plurality of cell strings; a first encapsulating adhesive film and a second encapsulating adhesive film that are stacked, where there is a gap between the first encapsulating adhesive film and the second encapsulating adhesive film; where the photovoltaic module has a central region and a peripheral region surrounding the central region, and the plurality of cell strings are disposed in the central region, where the first encapsulating adhesive film defines at least one first hole in the peripheral region, and the second encapsulating adhesive film defines at least one second hole in the peripheral region, and each first hole is aligned with a corresponding second hole and the at least one first hole and the at least one second hole include one or more through holes; and at least one filling structure each being filled in a respective first hole and a respective second hole, where the at least one filling structure includes a material having a crosslinking curing speed that is faster than a crosslinking curing speed of a material in the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material in the second encapsulating adhesive film.