Solar Cell Back Panel Laminate for Simpler Weather-Resistant Packaging
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Solution Overview
Problem
Conventional back panels for solar cell modules require complex manufacturing processes involving multiple apparatuses and materials, and lack sufficient weather resistance, heat resistance, barrier properties, and impact strength, which can lead to damage and reduced efficiency.
Innovation Solution
A back panel structure comprising a prepreg formed by immersing a fiber substrate into a resin composition containing a first epoxy resin with phosphorus atoms and a fluorine-containing polymer layer, which is simpler to manufacture and provides improved weather resistance, heat resistance, and impact strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional back panel structure with PET plate, fluorine-containing polymer layer, and PVF layer is used, then good weather resistance, heat resistance, barrier property, and impact strength are achieved, but the manufacturing process becomes complex and requires multiple processing apparatuses
Solution Approach 1:
The patent combines the substrate function (PET plate) and the adhesive bonding function (PVF layer) into a single integrated back panel structure with a PET plate that has a PVF layer directly formed on its rear surface. This merging eliminates the need for separate substrate and adhesive layers, reducing manufacturing complexity while maintaining weather resistance and bonding performance.
Solution Approach 2:
The PET plate in the invention serves multiple functions simultaneously: it provides structural support, weather resistance, and adhesive bonding capability through the integrated PVF layer. This multi-functionality reduces the number of separate components needed, simplifying the manufacturing process while maintaining all required performance characteristics.
2Reliability
If multiple lamination and adhesive coating steps are performed in the back panel manufacturing process, then good barrier property and impact strength are achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The PVF layer is pre-formed on the PET plate surface during the back panel manufacturing process itself, rather than being applied separately later. This preliminary integration of the adhesive layer reduces subsequent manufacturing steps and time required, while ensuring proper bonding capability from the outset.
3Strength
If additional lamination packaging is required when applying the back panel to the solar cell module, then good impact strength is achieved, but the overall manufacturing complexity increases
Solution Approach 1:
The protective and bonding functions are merged into a single integrated back panel structure where the PVF layer serves both as the protective outer surface and as the adhesive bonding layer. This eliminates the need for additional separate lamination packaging steps, reducing manufacturing complexity while maintaining impact strength.
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
The new back panel design enhances weather resistance, heat resistance, and impact strength, allowing for a simpler manufacturing process and increased light conversion efficiency in solar cell modules.
Implementation Method 1
Based on a total weight of the resin composition being 100 PHR (parts per hundred resin), the resin composition includes: 5 PHR to 70 PHR of a first epoxy resin, 1 PHR to 20 PHR of a hardener and 0.01 PHR to 10 PHR of an accelerant. The first epoxy resin contains phosphorus atoms, and an amount of the phosphorus atoms in the first epoxy resin ranges from 0.1 wt % to 5 wt %.
Implementation Method 2
the fluorine-containing polymer layer enables the back panel to possess good weather resistance, good heat resistance, a good barrier property, and a good impact strength
Implementation Method 3
the prepreg is formed by immersing a fiber substrate into a resin composition. Based on a total weight of the resin composition being 100 PHR (parts per hundred resin), the resin composition includes: 5 PHR to 70 PHR of a first epoxy resin, 1 PHR to 20 PHR of a hardener and 0.01 PHR to 10 PHR of an accelerant.
Data Source
AI summary
A back panel of a solar cell and a method for manufacturing the same are provided. The back panel includes a prepreg and a fluorine-containing polymer layer, and the fluorine-containing polymer layer is formed on the prepreg. The prepreg is formed by immersing a fiber substrate into a resin composition. Based on a total weight of the resin composition being 100 PHR (parts per hundred resin), the resin composition includes: 5 PHR to 70 PHR of a first epoxy resin, 1 PHR to 20 PHR of a hardener, and 0.01 PHR to 10 PHR of an accelerant. The first epoxy resin contains phosphorus atoms, and an amount of the phosphorus atoms in the first epoxy resin ranges from 0.1 wt % to 5 wt %.