Solar Battery Assembly Laminating Process for Bubble-Free Bonding
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Solution Overview
Problem
Current solar battery assembly formation methods face challenges such as bubble formation, uneven binding agent distribution, and low yield rate due to difficulties in achieving uniform pressure and air-tightness, especially for arched shapes, leading to suboptimal performance and increased production costs.
Innovation Solution
A method involving cold and hot vacuuming processes at controlled temperatures and pressures, using a sealing sleeve with apertures to ensure uniform pressure and prevent bubble formation, combined with a non-contact static laminating process to enhance the bonding of glass plates, solar cells, and a hard back sheet, allowing for the production of solar battery assemblies with improved mechanical performance and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an elastic layer is used for dynamic laminating, then the laminating process can be performed, but uneven pressure is applied causing bubble formation and solar cell breaking
Solution Approach 1:
The patent replaces the mechanical elastic layer system with a vacuum-based system. Instead of using an elastic layer that applies uneven mechanical pressure, the invention uses vacuum suction through aperture-forming rollers to uniformly remove air and apply consistent pressure across the entire solar battery assembly surface, eliminating bubble formation while maintaining ease of manufacture.
Solution Approach 2:
The patent employs pneumatic principles by using vacuum suction through aperture-forming rollers. The vacuum system creates uniform negative pressure across the assembly, allowing the binding agent to evenly distribute and bond layers without the uneven pressure distribution caused by elastic layers, thus preventing bubbles and cell breaking.
2Strength
If a hard back sheet is used, then the appearance and structural integrity are improved, but uniform pressure application becomes difficult leading to binding agent unevenness and bubbles
Solution Approach 1:
The patent replaces direct mechanical pressure application with vacuum suction. The aperture-forming rollers create vacuum channels that uniformly extract air from between the hard back sheet and other layers, allowing the binding agent to evenly distribute without being obstructed by uneven pressure, thus achieving both strong bonding and uniform appearance.
Solution Approach 2:
The patent changes the pressure application method from positive mechanical pressure (which is difficult to control uniformly on hard surfaces) to negative vacuum pressure. This parameter change allows uniform pressure distribution across the hard back sheet, ensuring even binding agent distribution and eliminating bubbles while maintaining the structural integrity of the hard back sheet.
3Device complexity
If traditional overlapping and heating lamination is used, then the process is simple, but air-tightness cannot be ensured due to bubble formation
Solution Approach 1:
The patent introduces a vacuum system with aperture-forming rollers that create uniform negative pressure across the assembly. This pneumatic approach actively removes air bubbles during the binding agent application process, ensuring air-tightness is achieved while maintaining relatively simple equipment compared to complex multi-stage heating and pressing systems.
4Reliability
If vacuuming is performed to remove bubbles, then air-tightness is improved, but binding agent may become uneven without controlled pressure
Solution Approach 1:
The patent combines vacuum suction with controlled pressure application through aperture-forming rollers. The vacuum removes air bubbles while the rollers simultaneously apply uniform pressure to ensure even binding agent distribution. This dual action achieves both air-tightness and uniform binding agent distribution without the trade-off present in separate processes.
Solution Approach 2:
The patent merges the vacuuming function and pressure application function into a single integrated system. The aperture-forming rollers perform both vacuum suction to remove bubbles and pressure application to distribute binding agent evenly, eliminating the need for separate processes and avoiding the trade-off between air-tightness and binding agent uniformity.
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 method significantly reduces bubble occurrence and solar cell fragmentation, increases yield rate, and enables the production of solar battery assemblies with enhanced mechanical performance and appearance, suitable for various shapes, including arched designs, while reducing manufacturing costs and improving scalability.
Implementation Method 1
performing cold vacuuming at a temperature of about 0-50°C and hot vacuuming at a temperature of about 50-200°C to a glass plate, a pfuratity of solar cells and a back sheet laminated in turn and adhered together
Implementation Method 2
treating the laminated glass plate, the plurality of solar cells and the back sheet obtained in step (a) with a temperature of about 100-200°C and a pressure of about 0.5~1.5 MPa
Data Source
Figure 1
AI summary
A method for forming a solar battery assembly is provided, comprising the following steps: a) performing cold vacuuming at a temperature below about 0~50? and hot vacuuming at a temperature of about 50~200? to a glass plate, a plurality of solar cells (1) and a back sheet laminated in turn and adhered together; and b) treating the laminated glass plate, the plurality of solar cells (1) and the back sheet obtained in step (a) with a temperature of about 100~200? and a pressure of about 0.5~1.5MPa to obtain the solar battery assembly. A solar battery assembly is also provided.