Photovoltaic Module Inactive Zone Minimization via Insulating Strips
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Solution Overview
Problem
Existing photovoltaic module manufacturing methods face challenges in minimizing inactive zones and maximizing active zones, leading to reduced efficiency due to edge effects and physical properties of materials and supports.
Innovation Solution
A method involving the formation of electrically insulating strips to define inactive zones and the use of specific surface energy and tension differences in liquid formulations for depositing conductive materials, allowing for thinner inactive zones and optimized active zone area ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wet deposition is used to manufacture stacking layers, then large-scale production is enabled, but inactive zone width increases due to edge effects and material properties
Solution Approach 1:
The patent applies preliminary action by forming the inactive zone definition structure (grooves with insulating material) on the substrate before depositing the active stacking layers. This pre-defined structure guides the subsequent wet deposition process, allowing the liquid formulation to be deposited precisely within the active zones without encroaching into inactive areas, thus minimizing inactive zone width while maintaining large-scale production capability through wet deposition methods
2Area of stationary object
If inactive zone width is reduced to maximize active zone area, then geometric fill-factor improves, but manufacturing precision requirements increase due to rheological and wettability constraints
Solution Approach 1:
The patent introduces an intermediary structure consisting of grooves filled with electrically insulating material that acts as a physical barrier and guide for the liquid formulation deposition. This intermediary structure mediates between the conflicting requirements by providing clear boundaries that prevent edge effects and ensure precise deposition within active zones, thereby enabling high geometric fill-factor while maintaining manufacturability through wet deposition processes
Solution Approach 2:
The patent applies parameter changes by optimizing the surface energy and wettability parameters of the liquid formulation to ensure proper interaction with the substrate and groove structures. By controlling these parameters, the liquid formulation can be precisely confined to active zones during wet deposition, achieving both high active zone area and acceptable manufacturing precision
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 approach minimizes inactive zone width, maximizes active zone area, and enhances the geometric fill-factor of photovoltaic modules, improving electrical efficiency and production compatibility with large-scale methods.
Implementation Method 1
deposition, on the groove and on the first electrically conductive material, of a first liquid formulation of insulating material, followed by a transition of said first formulation to the solid state
Implementation Method 2
the deposition of the first liquid formulation creates a first interface with said first electrically conductive material, the first surface tension of said first interface being less than said first surface energy
Implementation Method 3
a difference between said first surface energy and said first surface tension being preferably between 0.015 Nm-1 and 0.025 N.m -1
Data Source
Figure 1~6
AI summary
The present invention relates to a method for manufacturing a photovoltaic module (10), comprising the following steps: forming, on an electrically conductive material, a groove (20A) defining a first (18A) and a second (18B) lower electrode; then forming on each lower electrode a stack (34) comprising at least one upper electrode (36) and an intermediate photoactive layer (38), to form respectively a first (16A) and a second (16B) photovoltaic cell; then forming an electrical connection (17A) between said cells (16A, 16B). Before the stacks are formed, a first insulating strip (22A) is formed in the groove (20A); and a second insulating strip (24B) is formed on the second lower electrode, delimiting an inactive zone (28B) on said second electrode. The stack (34) subsequently formed on the second cell is disposed outside of said inactive area.