Solar Cell Assembly Thermal Injection Molding
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Solution Overview
Problem
Conventional lamination processes for solar cell assembly lead to deformation, cracking, and poor product uniformity due to manual operation, inaccuracy, and environmental issues, making them unsuitable for large solar cells with fragile and thin structures.
Innovation Solution
A thermal injection molding process is used instead of lamination, employing specific encapsulation materials and automatic injection into molds to encapsulate solar cell sheets, reducing defects and enhancing productivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional lamination process with pressurization treatment is used, then solar cell sheets can be integrated into assembly, but deformation, damage and cracking occur in solar cell sheets
Solution Approach 1:
The patent replaces the conventional mechanical pressurization system with a vacuum-based system. Instead of applying direct pressure that causes deformation and cracking, the invention uses vacuum pressure to hold and integrate solar cell sheets, eliminating the harmful mechanical stress while maintaining assembly integration
Solution Approach 2:
The patent changes the pressure parameter from positive pressure (conventional lamination) to negative pressure (vacuum environment). This parameter change allows the solar cell sheets to be integrated without experiencing the deforming forces that cause damage and cracking
2Ease of manufacture
If manual lamination operation is used, then solar cell assembly can be fabricated, but product uniformity and quality stability are poor due to inaccuracy
Solution Approach 1:
The patent employs a vacuum system that automatically holds and positions solar cell sheets through atmospheric pressure differential. This self-adjusting mechanism eliminates manual positioning errors and ensures consistent, accurate placement without requiring operator skill or attention
Solution Approach 2:
The patent replaces manual mechanical operations with an automated vacuum-based system. The vacuum environment provides automatic, uniform holding force across all solar cell sheets, eliminating the variability and inaccuracy inherent in manual lamination operations
3Ease of manufacture
If conventional lamination process is used, then solar cell assembly can be encapsulated, but productivity is limited and material waste occurs
Solution Approach 1:
The patent combines multiple solar cell sheets and encapsulation materials into a single vacuum chamber environment. This allows simultaneous processing of multiple components in one operation, eliminating sequential manual steps and significantly improving production efficiency while reducing material waste through precise vacuum-controlled placement
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 results in higher product uniformity, improved electrical performance, longer lifetime, and reduced material waste, making it suitable for large solar cells with enhanced durability and efficiency.
Implementation Method 1
a thermal injection molding process is used instead of a lamination process
Implementation Method 2
injecting an injection molding material into the plurality of casting molds under a heating condition
Data Source
AI summary
A fabrication method for a solar cell assembly is disclosed. Solar cell sheets, which are connected to each other with connecting sheets, are placed into an injection mold having casting molds. The solar cell sheets are respectively situated in the casting molds. An injection molding material is injected into the casting molds under a heating condition such that the solar cell sheets are encapsulated in the injection molding material. The injection molding material can include ethylene-vinyl acetate or polysilicone and polyvinyl butyral. The encapsulated solar cell sheets are taken out of the injection mold. A substrate and a back sheet respectively are attached to two sides of the encapsulated solar cell sheets.