Reflective Encapsulant Grid for Simpler PV Module Lamination
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Solution Overview
Problem
Conventional methods for adding a reflective layer to photovoltaic modules are complex, energy-intensive, and time-consuming, complicating the fabrication process and increasing material costs.
Innovation Solution
A process involving an aqueous pigment-polyolefin dispersion is applied as a grid-pattern onto a rear encapsulant film, forming a gridded rear encapsulant film with a reflective grid layer, which is then dried to create a reflective photovoltaic module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional techniques (melt bonding, additional structural layers) are used to add a reflective layer to PV modules, then light reflection is enhanced, but device complexity and material costs increase
Solution Approach 1:
The patent combines the reflective layer and encapsulant layer into a single integrated component. The reflective encapsulant layer simultaneously provides encapsulation protection and light reflection functionality, eliminating the need for separate reflective layers and tie layers, thus reducing structural complexity while maintaining or enhancing light reflection efficiency
Solution Approach 2:
The reflective encapsulant layer serves multiple functions: (1) electrical insulation between cells, (2) mechanical protection and encapsulation, (3) light reflection to enhance PV cell efficiency, and (4) structural support. This multi-functional design eliminates the need for separate components, reducing overall device complexity
2Ease of manufacture
If conventional lamination procedures are used for PV module fabrication, then module assembly is achieved, but energy consumption and fabrication time increase
Solution Approach 1:
The patent changes the chemical composition parameters of the encapsulant material to include reflective pigments (such as titanium dioxide, zinc oxide, or barium sulfate) directly integrated into the polymer matrix. This compositional change allows the encapsulant to provide both encapsulation and reflection functions without requiring high-energy lamination processes, thereby reducing energy consumption while maintaining manufacturing feasibility
3Ease of manufacture
If conventional lamination procedures are used for PV module fabrication, then module assembly is achieved, but fabrication time increases
Solution Approach 1:
By merging the reflective layer and encapsulant layer into a single integrated component, the patent reduces the number of fabrication steps. Instead of separately applying and bonding reflective layers and encapsulant layers, the integrated reflective encapsulant can be applied in a single step, significantly reducing fabrication cycle time while maintaining complete module assembly functionality
Solution Approach 2:
The reflective properties are built into the encapsulant material itself during material production, rather than requiring subsequent application steps. This preliminary integration of functionality into the base material eliminates later processing steps, reducing overall fabrication time
4Use of energy by moving object
If conventional techniques with additional structural layers are used, then reflective functionality is achieved, but material costs increase
Solution Approach 1:
The patent merges multiple material functions into a single material layer, eliminating the need for separate reflective layers, tie layers, and encapsulant layers. This consolidation reduces the total quantity of materials required while maintaining all necessary functions including light reflection, electrical insulation, and mechanical protection
Solution Approach 2:
The reflective encapsulant layer serves as a multi-functional material that simultaneously provides structural support, electrical insulation, mechanical protection, and light reflection. This eliminates the need for multiple separate material layers, reducing overall material quantity and cost while achieving all required functionalities
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 PV module fabrication process, reduces energy consumption, and lowers material costs while enhancing light reflection for improved efficiency.
Implementation Method 1
A reflective grid layer is formed by drying a grid pattern of the aqueous dispersion applied to a rear encapsulant film of a photovoltaic module
Data Source
AI summary
The present disclosure provides a process. In an embodiment, the process includes providing an aqueous pigment-polyolefin dispersion (P-P dispersion) and applying a grid-pattern of the aqueous P-P dispersion onto a rear encapsulant film. The process includes drying the grid-pattern into a grid layer to form a gridded rear encapsulant film. The process includes placing a plurality of photovoltaic cells and a front encapsulant film onto the gridded rear encapsulant film to form a stack, and laminating the stack to form a reflective photovoltaic (PV) module. The present disclosure also provides a reflective photovoltaic module produced by the process.