Roll-Up Screen Solar Cell Encapsulation for Easy Winding

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Solution Overview

Problem

Conventional roll-up screen devices with solar cells are thick and hard due to the arrangement of solar cells and encapsulants, making them difficult to wind up.

Innovation Solution

A roll-up screen device with a fabric layer, a first encapsulation layer, solar cells on the first encapsulation layer, a second encapsulation layer, and a coating layer between the fabric and first encapsulation layer to prevent encapsulant penetration, maintaining fabric layer stiffness and improving winding ease.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If solar cells and encapsulant are arranged on the fabric layer in the screen, then the screen provides solar cell functionality, but the screen becomes thick and hard, making it difficult to wind up

Engineering Contradiction:

Improvesolar cell functionalityVSAvoidease of winding

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

A coating layer is introduced as an intermediary between the fabric layer and the first encapsulation layer. This coating layer serves as a barrier that prevents the encapsulant from penetrating into the fabric layer, thereby maintaining the flexibility and windability of the screen while preserving the solar cell functionality. The coating layer mediates between the rigid encapsulation structure and the flexible fabric substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating layer is implemented as a thin film structure that maintains the overall flexibility of the screen assembly. By using a thin film approach rather than thick rigid structures, the screen retains its ability to be wound up while still providing the necessary barrier function to prevent encapsulant penetration.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If solar cells and encapsulant are arranged on the fabric layer, then the screen provides structural support, but the screen becomes thick and hard

Engineering Contradiction:

Improvestructural supportVSAvoidthickness and hardness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The coating layer acts as a mediator that allows the encapsulation layer to provide structural support without directly contacting and stiffening the fabric layer. This intermediate barrier enables the screen to maintain its structural integrity while preventing the encapsulant from making the fabric layer thick and hard.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating layer is applied locally at the interface between the fabric layer and the encapsulation layer, providing targeted reinforcement and barrier function only where needed. This localized approach maintains structural support while minimizing the overall impact on the screen's flexibility and thickness.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250215747A1Roll-up screen device

Publication Date: 2025.07.03 LIXIL CORP

AI summary

A roll-up screen device includes a sheet-shaped screen, and a wind-up mechanism that winds the screen. The screen includes a fabric layer, a first encapsulation layer on the fabric layer, a solar cell on the first encapsulation layer, a second encapsulation layer on the solar cell, and a coating layer provided on a surface of the fabric layer facing the first encapsulation layer to restrain an encapsulant constituting the first encapsulation layer from entering the fabric layer.