PV Module Lamination Using Low-Pressure Polymer Encapsulation
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Solution Overview
Problem
Conventional lamination processes for photovoltaic modules face challenges such as edge pinching, thickness variation, bubble formation, and delamination issues due to high pressures and temperatures, which affect the quality and performance of the final product.
Innovation Solution
A lamination process that uses a polymer composition with a thermoplastic polymer, such as ethylene-based polymers with silane group-containing units, and applies pressure gradually at 790 mbar or below, reducing the need for high pressures and temperatures, thereby minimizing thickness variation and preventing delamination and bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure (800-1000 mbar) is applied during lamination, then proper lamination occurs, but edge pinching and thickness variation occur
Solution Approach 1:
The patent changes the pressure parameter from conventional high pressure (800-1000 mbar) to reduced pressure (50-500 mbar). This parameter change resolves the contradiction by enabling proper lamination at lower pressures, thus avoiding edge pinching and thickness variation while maintaining lamination quality
Solution Approach 2:
The patent uses a composite polymer composition comprising ethylene-vinyl acetate copolymer and ethylene-acrylate copolymer in specific ratios. This composite material provides optimized rheological properties that enable effective lamination at reduced pressures, resolving the contradiction between achieving proper lamination and avoiding thickness defects
2Stability of the object's composition
If high temperature is applied during lamination, then polymer melting occurs, but stress on photovoltaic cells increases causing rupture
Solution Approach 1:
The patent modifies the temperature parameter by conducting lamination at reduced temperatures (60-100°C) compared to conventional high temperature processes. This parameter change allows the polymer composition to achieve proper melting and bonding while minimizing thermal stress on photovoltaic cells, thus preventing cell rupture
Solution Approach 2:
The composite polymer composition with specific copolymer ratios provides optimized melting characteristics at lower temperatures. This material composition enables the lamination process to achieve proper polymer flow and bonding at reduced temperatures, resolving the contradiction between ensuring polymer melting and protecting cell integrity
3Productivity
If fast lamination cycle is implemented, then productivity increases, but delamination and bubble formation occur
Solution Approach 1:
The patent changes the pressure and temperature parameters to optimized reduced values that enable faster heat transfer and more efficient lamination. This allows achieving proper bonding quality in shorter cycle times, thus resolving the contradiction between increasing productivity and preventing delamination
Solution Approach 2:
The composite polymer composition provides optimized viscosity and flow characteristics that enable rapid wetting and bonding during lamination. This material property allows the process to achieve complete bonding in shorter times, resolving the contradiction between fast cycle time and preventing bonding defects
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 process results in a multilayer laminate with reduced thickness variation, less internal stress, and improved adhesion, leading to enhanced performance and extended lifespan of the photovoltaic modules.
Implementation Method 1
heating step to heat up the multilayer assembly optionally in a chamber at evacuating conditions
Implementation Method 2
heating step to heat up the multilayer assembly optionally in a chamber at evacuating conditions
Data Source
AI summary
The present invention relates to a lamination process for producing a multilayer laminate, preferably to a lamination process for producing a photovoltaic (PV) module, and to a PV module laminate.