Automated Reel Solar Module Production with Flexible Encapsulation
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Solution Overview
Problem
Conventional solar module production methods are inefficient, leading to yield loss and structural issues during transportation and installation due to the weight and fragility of glass backsheet modules, which require extensive wiring and intermediate curing steps, and often result in cracks and failures.
Innovation Solution
An automated reel process for producing solar modules that creates long, flexible sheets with modular electrical connections, allowing for continuous production without interruptions, using a system that includes encapsulation, inspection, and in-line bussing with bypass diodes, and flexible or rigid sheets that can be wound onto reels for transportation and storage, simplifying field connections and reducing structural requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional glass backsheet modules are used, then structural strength is maintained, but weight increases and handling difficulty increases
Solution Approach 1:
The patent changes the physical state and material composition of the module from rigid glass backsheet to flexible encapsulated structure, transforming the mechanical properties while maintaining structural integrity through alternative materials and design
Solution Approach 2:
The patent employs flexible encapsulation materials and thin-film structures to replace traditional rigid glass backsheets, achieving both weight reduction and maintained strength through flexible protective layers that conform to the solar cell structure
2Productivity
If automated reel process is used, then productivity increases, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations (encapsulation, bussing, diode installation, inspection) into a single continuous automated reel process, eliminating intermediate steps and curing cycles to achieve continuous production
Solution Approach 2:
The patent implements a continuous manufacturing process where solar cells are encapsulated, bussed, and inspected in an uninterrupted reel-to-reel operation, eliminating batch processing and intermediate storage to maintain continuous production flow
3Loss of time
If intermediate curing steps are required, then bonding strength is achieved, but production time increases
Solution Approach 1:
The patent eliminates intermediate curing steps by implementing continuous encapsulation and bonding operations that maintain constant pressure and temperature conditions throughout the process, allowing bonding to occur continuously without interruption
Solution Approach 2:
The patent prepares all bonding surfaces and applies all encapsulation materials in advance during the continuous reel process, ensuring that when components are joined, the bonding conditions are already optimized and no additional curing time is required
4Ease of operation
If glass backsheet modules are used, then protection is provided, but handling difficulty increases and cracks occur
Solution Approach 1:
The patent replaces rigid glass backsheets with flexible encapsulation films that provide protection while allowing the module to bend and flex during handling, eliminating the brittleness that causes cracking in glass-based modules
Solution Approach 2:
The patent uses composite encapsulation structures combining multiple materials with complementary properties to provide both protection and flexibility, creating a multi-layer system that protects solar cells while maintaining handling ease
Data Source
AI summary
This specification describes automated reel processes for producing solar modules and solar module reels. In some examples, a method includes receiving a continuous feed of photovoltaic devices on a photovoltaic device sheet. The method includes locating and bypassing one or more defective photovoltaic devices on the photovoltaic device sheet. The method includes installing bussing for the photovoltaic devices on the photovoltaic device sheet. The method includes feeding the photovoltaic device sheet to an encapsulation system to output a photovoltaic module sheet.