Planarization Material for PV Layer Lamination
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Solution Overview
Problem
The uneven topography of photovoltaic (PV) layers causes localized point loads during lamination processes, leading to cracking and shunting, which reduces the performance and reliability of optoelectronic components and impacts production yield.
Innovation Solution
The application of a planarization material, such as thermoplastics or thermoset films, to create a planar surface on PV layers, which distributes forces evenly during lamination, reducing the likelihood of cracking and shunting by embedding surface irregularities within the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the PV layer is laminated using autoclave process with pressure and heating, then the integration of PV layers into industrial components is achieved, but the uneven topography of PV layers causes localized point loads leading to cracking and shunting
Solution Approach 1:
A planarization layer is introduced as an intermediary between the PV layer and the lamination structure. This planarization layer has a dual function: it provides a planar upper surface for uniform pressure distribution during autoclave lamination, and it conforms to the uneven lower surface of the PV layer, thereby eliminating localized point loads that cause cracking and shunting.
2Productivity
If pressure is applied during de-airing or autoclave lamination, then the lamination process is completed, but the uneven surface of PV layer creates localized point loads that reduce performance and reliability
Solution Approach 1:
The planarization layer is applied to the PV layer before the lamination process begins. This preliminary action creates a planar surface that will maintain uniform contact during subsequent pressure application in de-airing and autoclave lamination, preventing localized point loads and ensuring consistent manufacturing quality throughout production.
3Device complexity
If the PV layer surface is left uneven with protrusions and depressions, then the original PV structure is maintained, but localized point loads occur during compression that cause defects
Solution Approach 1:
The planarization layer exhibits different local properties at different heights: at the lower level it conforms to and supports the uneven PV layer surface, while at the upper level it provides a uniformly planar surface. This local quality variation allows the structure to simultaneously accommodate the original PV complexity and provide uniform stress distribution to prevent cracking.
Data Source
AI summary
Various processes can apply pressure and/or heat to a photovoltaic (PV) layer, including processes that integrate solar cells into different types of industrial glass such as an autoclave lamination process. The disclosure describes a planarization technique that can be used on the PV layer to eliminate point loads caused by such processes. In an aspect, a method for producing a component is described that includes disposing or placing a planarization material on a PV layer, modifying a physical form of the planarization material to provide a planar surface made of the planarization material on one side of the PV layer having surface irregularities, and forming a stack of layers (e.g., as part of an autoclave lamination process) for the component by disposing a first layer over the planar surface on the one side of the PV layer and a second layer over the other, opposite side of the PV layer.