Solar Cell Encapsulation Module with Metal Particle Layer
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Solution Overview
Problem
The manufacturing process of back contact solar cells faces challenges such as stress in tandem connections, ineffective tandem connections, cell fragmentation, and low photoelectric conversion efficiency, which are not adequately addressed by conventional encapsulation methods.
Innovation Solution
A solar cell encapsulating module is developed, comprising a light transmittance first substrate, a metal particle layer, a routing layer, and a second encapsulating material layer, where the metal particle layer is applied to enhance photoelectric conversion efficiency and the precuring process reduces the risk of fragmentation, with the routing layer disposed on only one side of the solar cells for efficient electrical interconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If both N-pole electrode and P-pole electrode are disposed on the back side of the solar cell (back contact design), then the output electric current is enhanced and encapsulating loss is reduced, but stress in tandem connection increases and cell fragmentation risk increases
Solution Approach 1:
The patent segments the electrode configuration by placing N-pole electrodes on the front side and P-pole electrodes on the back side, rather than concentrating both on the back side. This segmentation reduces stress concentration in tandem connections while maintaining high output current through optimized electrode distribution and routing layer design.
Solution Approach 2:
The patent implements a precuring process before lamination to pre-stabilize the solar cell structure and reduce internal stresses. This preliminary action prevents cell fragmentation during subsequent manufacturing steps while maintaining the benefits of back contact design for enhanced power output.
2Ease of manufacture
If conventional encapsulation methods are used for back contact solar cells, then the manufacturing process is simple, but ineffective tandem connection and cell fragmentation occur
Solution Approach 1:
The patent introduces a precuring step before lamination to pre-stabilize the solar cell structure and reduce internal stresses. This preliminary action prevents cell fragmentation during subsequent manufacturing steps while maintaining the benefits of back contact design for enhanced power output.
Solution Approach 2:
The patent introduces a routing layer as an intermediary component between the solar cells and encapsulation materials. This routing layer facilitates effective tandem connections by providing dedicated pathways for electrical interconnection, thereby improving reliability without significantly complicating the manufacturing process.
3Power
If metal particle layer is added to enhance photoelectric conversion efficiency, then short circuit current density increases, but device complexity increases
Solution Approach 1:
The patent merges the metal particle layer enhancement technique with the back contact solar cell design by integrating it into the existing encapsulation module structure. The metal particles are incorporated into the encapsulation materials or routing layer, combining optical enhancement with electrical interconnection functions without significantly increasing device complexity.
Solution Approach 2:
The patent modifies optical parameters of the encapsulation module by introducing metal particles with specific optical properties (plasmon resonance, light scattering) to enhance photoelectric conversion. This parameter change approach improves power output while maintaining structural simplicity through controlled material composition changes rather than structural additions.
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 solution enhances photoelectric conversion efficiency, reduces the risk of solar cell fragmentation, and improves the production yield rate by using a metal particle layer and precuring process in the encapsulating module, resulting in increased short circuit current density and improved fill factor.
Implementation Method 1
the metal particle layer is applied to enhance photoelectric conversion efficiency
Implementation Method 2
enhance photoelectric conversion efficiency, reduces the risk of solar cell fragmentation
Data Source
AI summary
The disclosure provides a solar cell encapsulating module including a first substrate, a first encapsulating material layer, a metal particle layer, multiple solar cells, a routing layer, a second encapsulating material layer and a second substrate. The first substrate is formed from a light transmittance material. The first encapsulating material layer is formed on the first substrate. The metal particle layer is formed on the first encapsulating material layer. The solar cells are disposed on the metal particle layer. The routing layer is disposed on the solar cells for being electrically connected to the plurality of solar cells. The second encapsulating material layer is formed on the routing layer. The second substrate is disposed on the second encapsulating material layer. The routing layer is disposed on only one side of the solar cells.