PV Module Lamination Using Isotropic Polymer Ribbon Bonding
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Solution Overview
Problem
The existing photovoltaic (PV) module production process is complex and costly due to the need for distinguishing the front and back sides of multi-layer polymer films for bonding solder ribbons to solar cells, leading to increased material consumption and manufacturing costs.
Innovation Solution
A method using a single layer of isotropic polymer material for bonding solder ribbons to crystalline silicon solar cells, followed by heating to ensure stable bonding without affecting electrical connections, and subsequent lamination to form a PV module, eliminating the need to differentiate film sides and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-layer polymer films are used for bonding solder ribbons to solar cells, then bonding stability is improved, but process complexity and material costs increase due to the need to distinguish front and back sides
Solution Approach 1:
The patent applies homogeneity by using a single-layer isotropic polymer material instead of multi-layer anisotropic films. The isotropic nature means the material has uniform properties in all directions, eliminating the need to distinguish front and back sides. This resolves the contradiction by maintaining bonding stability through the polymer's adhesive properties while removing the complexity of orientation-dependent multi-layer structures
Solution Approach 2:
The patent extracts the essential bonding function from complex multi-layer films and implements it through a single-layer isotropic polymer material. By taking out only the necessary adhesive functionality and removing unnecessary layers with different adhesion properties, the solution achieves stable bonding without the complexity of distinguishing film sides
2Reliability
If multi-layer polymer films are used for bonding, then bonding performance is improved, but material consumption and costs increase
Solution Approach 1:
The patent extracts the essential bonding function from multi-layer films and implements it through a single-layer isotropic polymer material. By removing redundant layers, the solution reduces material consumption while maintaining the necessary bonding performance through the polymer's adhesive properties
Solution Approach 2:
The single-layer isotropic polymer material provides uniform bonding performance across the entire film, eliminating the need for multiple layers with different adhesion properties. This homogeneous approach reduces material consumption while achieving reliable bonding
3Reliability
If conventional thermal soldering is used, then electrical connection is achieved, but solar cell cracks and hidden defects occur
Solution Approach 1:
The patent replaces the mechanical thermal soldering process with a polymer-based bonding system. Instead of using high-temperature soldering that causes thermal stress and cracks, the isotropic polymer material provides mechanical bonding through adhesion, eliminating the harmful thermal effects while maintaining electrical connection through the conductive properties of the polymer or embedded conductive elements
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 simplifies the process, lowers costs, and ensures stable bonding without compromising electrical performance or light transmission in the PV module.
Implementation Method 1
covering a first polymer material on the at least side of the crystalline silicon solar cell where the solder ribbon is placed, followed by heating at a first temperature to bond the polymer material to the crystalline silicon solar cell
Implementation Method 2
heating at a first temperature to bond the polymer material to the crystalline silicon solar cell, so as to attach the solder ribbon to the crystalline silicon solar cell
Implementation Method 3
subjecting the stacked body obtained in step (S2) to lamination at a second temperature to enable a soldering layer of the solder ribbon to be melted and soldered with a grid line
Implementation Method 4
enable a soldering layer of the solder ribbon to be melted and soldered with a grid line of the crystalline silicon solar cell to form an ohmic contact
Implementation Method 5
allow softening of the first polymer material and the second polymer material to form a filler layer to package the solar cell array
Implementation Method 6
subjecting the stacked body obtained in step (S2) to lamination at a second temperature
Data Source
AI summary
A method for fabricating a photovoltaic (PV) module, including: (1) covering a polymer material on the side of the crystalline silicon solar cell attached with a solder ribbon followed by heating to allow bonding of the solder ribbon to the crystalline silicon solar cell, so as to obtain a solar cell module; (2) assembling several solar cell modules into a solar cell string, and connecting multiple solar cell strings to form a solar cell array; (3) laying sealing plates respectively on the front and back sides of the solar cell array to form a stacked body; and (4) subjecting the stacked body to lamination achieve an ohmic contact between the solder ribbon and the grid line, and transformation of the polymer material into a filler layer. This application further provides a PV module fabricated by such method, a solar cell module and a solar cell string.