Photovoltaic Module Reflective Layer for Inactive Area Light Capture
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Solution Overview
Problem
Photovoltaic modules with monofacial or bifacial cells face inefficiencies due to inactive areas between cells and edge regions, which are not electrically active, leading to light loss and potential moisture ingress issues, particularly in polymer-based back sheets, and higher costs with glass-glass modules.
Innovation Solution
Incorporating a reflective layer with a sawtooth profile on the glass surfaces to redirect light incident on inactive areas through total internal reflection, enhancing light capture and reducing losses from glass and encapsulating materials, while maintaining electrical insulation and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymeric back sheet is used, then production cost is reduced, but protection against moisture ingress is insufficient
Solution Approach 1:
The patent employs a composite back sheet structure combining a polymeric base layer with a deposited inorganic layer (such as aluminum oxide or silicon oxide). This composite construction leverages the cost-effectiveness and flexibility of polymers while adding the moisture barrier properties of inorganic materials, thus resolving the contradiction between low production cost and effective moisture protection.
2Reliability
If glass is used instead of polymer back sheet, then protection against moisture ingress is improved, but production cost increases
Solution Approach 1:
The patent creates a hybrid back sheet system where a thin polymeric layer provides structural support and flexibility, while a deposited inorganic oxide layer delivers superior moisture barrier performance. This composite approach achieves glass-level protection at lower cost and with retained flexibility, resolving the contradiction between moisture protection and production cost.
Solution Approach 2:
The patent uses thin film deposition techniques to create a protective inorganic oxide layer on the polymeric back sheet. This thin film approach provides effective moisture barrier properties similar to glass while maintaining the flexibility and cost advantages of polymer materials, avoiding the need for expensive and rigid glass construction.
3Power
If electrical contacts are placed on both sides of cells, then electrical conductivity is improved, but risk of short circuit formation increases
Solution Approach 1:
The patent introduces a dielectric layer as an intermediary between the positive and negative electrical contacts on the same side of the cell. This dielectric barrier prevents direct contact between opposite polarities, eliminating short circuit risk while allowing both contacts to be positioned on the same side for improved conductivity and simplified interconnection.
4Productivity
If inactive areas between cells are minimized, then light capture is improved, but manufacturing complexity increases
Solution Approach 1:
The patent converts the previously harmful inactive areas between cells into beneficial light-trapping zones by applying reflective material to the back sheet in these regions. This transforms wasted space into active light-capturing areas that reflect light back through the cells, improving overall efficiency without requiring more complex cell arrangements or reducing inactive margins.
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 reflective layer system effectively captures and redirects light to active areas, improving photovoltaic module efficiency and durability by minimizing inactive area losses and moisture ingress, while potentially reducing production costs compared to glass-glass modules.
Implementation Method 1
Incorporating a reflective layer with a sawtooth profile on the glass surfaces to redirect light incident on inactive areas through total internal reflection
Data Source
AI summary
The present invention is applied to photo voltaic module enhanced light. In particular, the present invention relates to glass-glass and back contact photo photovoltaic modules with enhanced conversion efficiency in areas that are not usually active.