Concentrating Photovoltaic Sub-Module Single-Step Lamination
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Solution Overview
Problem
The manufacturing of concentrated photovoltaic sub-modules is complex and multi-step, requiring surface formation, polishing, bonding of photovoltaic cells, and vacuum laminations to avoid air bubbles, which complicates the process and increases the number of steps.
Innovation Solution
A single-step manufacturing method involving vacuum hot lamination of a multi-layer assembly with a structural element, a reflective face, a photovoltaic receiver, a transparent encapsulation material, and a protective layer, where the reflective face is shaped by contacting a convex counter-surface to achieve a concave predefined geometric shape, such as parabolic, using materials like EVA, polyolefin, and a reflective film with a silver or aluminum deposit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-step manufacturing methods are used for concentrated photovoltaic sub-modules, then bonding strength and adhesion are improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple manufacturing operations (lamination, shaping, bonding, and encapsulation) into a single integrated vacuum hot lamination step. The multi-layer assembly including structural element, reflective face, photovoltaic receiver, encapsulation material, and protective layer are all processed simultaneously, eliminating the need for separate bonding steps and reducing overall process complexity while maintaining reliable adhesion.
Solution Approach 2:
The vacuum hot lamination process serves multiple functions simultaneously: it bonds layers together, shapes the reflective face using a counter-form, encapsulates the photovoltaic receiver, and removes air bubbles. This multi-functional approach replaces several specialized manufacturing steps with a single versatile process.
2Manufacturing precision
If multiple vacuum laminations are performed to avoid air bubbles, then adhesion quality is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent performs air bubble removal, adhesion bonding, and encapsulation in a single vacuum hot lamination operation rather than multiple separate laminations. The vacuum environment eliminates air bubbles while the heat and pressure simultaneously bond all layers, achieving high adhesion quality in one step instead of multiple steps.
3Reliability
If separate bonding steps are used to attach photovoltaic cells to the mirror, then bonding reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The photovoltaic receiver is bonded to the structural element during the same vacuum hot lamination process that encapsulates it. The encapsulation material serves as the bonding medium, eliminating the need for separate adhesive application and bonding steps, thereby simplifying manufacturing while ensuring reliable mechanical and thermal attachment.
4Illumination intensity
If complex surface treatment and polishing steps are performed on the reflective surface, then optical performance is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The reflective face is pre-formed with the required concave geometric shape (such as parabolic) on the structural element before the lamination process. This preliminary shaping eliminates or minimizes the need for subsequent surface treatment and polishing steps, as the optical surface geometry is already established prior to encapsulation.
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 method simplifies the manufacturing process, ensures efficient heat dissipation and light concentration, and reduces the weight of the sub-modules while maintaining mechanical strength and optical functionality, resulting in a more efficient and cost-effective production of concentrated photovoltaic sub-modules.
Implementation Method 1
vacuum hot lamination of a multi-layer assembly
Implementation Method 2
the reflective face is shaped by contacting a convex surface of a counter- shape, to obtain the reflective face with a concave predefined geometric shape
Implementation Method 3
The parabolic shape of the module makes it possible to concentrate the light rays. The light arriving on a first sub-module is reflected by the reflecting surface
Implementation Method 4
Vacuum lamination thus makes it possible to ensure better adhesion of the optics, the cells or the wiring to their respective support
Implementation Method 5
vacuum hot lamination of a multi-layer assembly
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention relates to a method for producing a concentrating photovoltaic solar sub-module provided with a reflective face having a pre-defined geometric concave shape, characterised in that it comprises the lamination, in a single step, of a multi-layer assembly successively comprising: a structural element provided with a first reflective face and a second face opposite the first face; a photovoltaic receiver placed on the second face of the structural element; a layer of transparent encapsulation material, covering the photovoltaic receiver; and a transparent protection layer covering the layer of transparent encapsulation material, the transparent protection layer and the layer of encapsulation material covering at least all of the surface of the photovoltaic receiver; and in that, during the lamination, the reflective face of the structural element is shaped by being brought into contact with a convex surface of a counter-form, in order to obtain the reflective face with a pre-defined geometric concave shape.