Transparent Plastic PV Window Encapsulation With Index-Matched Fluid
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Solution Overview
Problem
Conventional solar photovoltaic module encapsulation techniques using glass are not well-suited for transparent plastics like PMMA and polycarbonate, as they struggle with applying uniform pressure, eliminating voids, and removing bubbles, especially when forming complex shapes.
Innovation Solution
The method involves encapsulating solar cells in transparent plastics with narrow cavities and using an optically coupling fluid with a refractive index matching the plastic, allowing for differential thermal expansion and reducing refractive distortion, while maintaining transparency and enabling electric power generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional glass encapsulation techniques are used with transparent plastics, then the manufacturing process can be maintained, but uniform pressure application, void elimination, and bubble removal become significantly more difficult
Solution Approach 1:
The patent changes the physical state of the encapsulant from solid (conventional EVA adhesive) to liquid (low-viscosity encapsulant), which fundamentally alters the lamination process. The liquid encapsulant flows to fill cavities and eliminates voids and bubbles more easily, resolving the manufacturing precision issue while maintaining ease of manufacture.
Solution Approach 2:
The patent uses vacuum pressure differentials to draw the liquid encapsulant into the cavities and remove air bubbles. The vacuum lamination process creates pressure gradients that drive the fluid encapsulant to fill all spaces, eliminating voids and bubbles that plague conventional solid adhesive methods.
2Adaptability or versatility
If solar cells are encapsulated in transparent plastics, then complex shapes and optical components can be formed, but applying uniform pressure to join components and eliminate voids becomes much more difficult
Solution Approach 1:
The patent changes the encapsulant from solid to liquid state, which allows it to conform to complex plastic shapes and fill cavities uniformly under vacuum pressure. The liquid flow properties enable even pressure distribution across irregular geometries, resolving the uniform pressure application difficulty.
Solution Approach 2:
The patent employs a dynamic lamination process where the liquid encapsulant flows and redistributes under vacuum pressure to achieve uniform distribution in complex shapes. The fluid adapts its configuration to match the cavity geometry, ensuring complete filling and void elimination in three-dimensional structures.
3Strength
If EVA adhesive is used for encapsulation, then the sandwich structure can be formed, but bubbles formed by out-gassing cannot be effectively removed
Solution Approach 1:
The patent uses vacuum pressure differentials to draw the liquid encapsulant into the cavities and remove air bubbles. The vacuum lamination process creates pressure gradients that drive the fluid encapsulant to fill all spaces, eliminating voids and bubbles that plague conventional solid adhesive methods.
Solution Approach 2:
The patent changes the physical state of the encapsulant from solid (conventional EVA adhesive) to liquid (low-viscosity encapsulant), which fundamentally alters the lamination process. The liquid encapsulant flows to fill cavities and eliminates voids and bubbles more easily, resolving the manufacturing precision issue while maintaining ease of manufacture.
4Illumination intensity
If refractive index matching is achieved between optically coupling fluid and plastic, then refractive distortion is reduced, but the fluid selection becomes more constrained
Solution Approach 1:
The patent specifies refractive index as a key parameter for the optically coupling fluid, requiring it to match the plastic encapsulation material. This parameter control minimizes optical distortion and maintains transparency, directly resolving the illumination intensity issue.
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 allows for the creation of photovoltaic window panes that absorb higher angle sunlight, reducing solar heat gain and enhancing electrical power production without obstructing views, while ensuring mechanical integrity and optical clarity.
Implementation Method 1
an optically coupling fluid with a refractive index matching the plastic, allowing for differential thermal expansion and reducing refractive distortion
Implementation Method 2
allows for differential thermal expansion
Implementation Method 3
encapsulating solar cells in transparent plastics
Data Source
AI summary
A product and a process for encapsulating solar cells in a module using transparent plastics and an optically coupling fluid. A photovoltaic window device of a construction that enables generation of electric power while simultaneously affording transparency.