Photovoltaic Module Sealing Layout for Bubble-Free Lamination
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Solution Overview
Problem
The use of a mixture of different sealing member materials in photovoltaic modules with varying cross-linking rates leads to bubbles and cavities during lamination, affecting the quality of the module due to the slower cross-linking rate of one material being extruded, resulting in holes and decreased performance.
Innovation Solution
A photovoltaic module structure that includes a first sealing member with a lower cross-linking rate, a second sealing member with a higher cross-linking rate, and a pad strip made of the same material as the first sealing member, arranged around the solar cell string, where the thicknesses of all components gradually decrease towards the edge, with the pad strip supplementing the first sealing member to reduce the occurrence of bubbles and cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a sealing member made of a mixture of EVA and POE is used to control cost, then the cost is reduced, but bubbles and cavities easily occur during lamination due to different cross-linking rates
Solution Approach 1:
The sealing member is divided into multiple layers with different materials (EVA layer and POE layer) having different cross-linking rates. Each layer is positioned at specific locations to control the cross-linking process separately, preventing bubble and cavity formation while maintaining cost effectiveness through the mixed material composition.
2Reliability
If POE sealing member is used to improve aging resistance and reduce water vapor transmission rate, then the performance is improved, but the cost increases
Solution Approach 1:
Different materials are used in different regions of the sealing member. The POE material, which provides superior aging resistance and lower water vapor transmission rate, is applied in specific layers or regions where these properties are most needed, while EVA is used in other areas, achieving localized performance optimization without uniformly increasing cost across the entire sealing member.
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 arrangement of the pad strip effectively reduces the possibility of bubbles and cavities during lamination, improving the quality and cost-effectiveness of the photovoltaic module by ensuring complete encapsulation and adhesion of the solar cell string.
Implementation Method 1
The sealing member can bond solar cells with a front glass and a back substrate
Implementation Method 2
Due to a difference in cross-linking rates of the EVA and POE, bubbles and cavities easily occur in the sealing member during lamination
Data Source
AI summary
A photovoltaic module includes a first sealing member, a pad strip, a solar cell string, and a second sealing member. A cross-linking rate of a material of the second sealing member is higher than that of a material of the first sealing member. The first sealing member, the solar cell string, and the second sealing member are sequentially arranged along a thickness direction of the photovoltaic module. The pad strip is located around the solar cell string and located between the first sealing member and the second sealing member. The pad strip is made of a same material as the first sealing member. A thickness of the first sealing member, a thickness of the second sealing member, and a thickness of the pad strip all gradually decrease along a length direction of the photovoltaic module towards an edge of the photovoltaic module.