Solar Cell Module Lower Substrate Moisture Barrier Design
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Solution Overview
Problem
The reliability of solar cell modules is frequently degraded due to moisture penetration, which affects their performance and longevity.
Innovation Solution
A solar cell module design featuring a lower substrate with a first, second, and third substrate configuration that surrounds the buffer part, folding inward to lengthen the moisture penetration route and potentially shielding the bus bar, thereby minimizing moisture ingress and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical solar cell module structure is used, then the manufacturing process is simple, but moisture penetrates easily into the periphery of the module, degrading reliability
Solution Approach 1:
The lower substrate is folded upward in a vertical direction to form a side wall that surrounds the buffer part. This dimensional change from a flat 2D substrate to a 3D structure with vertical walls creates a physical barrier that prevents moisture from penetrating along the periphery of the module, thereby improving reliability without requiring additional sealing components
Solution Approach 2:
The lower substrate is divided into two functional parts: a first lower substrate that supports the solar cells and a second lower substrate that forms the side wall surrounding the buffer part. This segmentation allows the single substrate to simultaneously perform both support and moisture barrier functions, resolving the contradiction between simplicity and reliability
2Reliability
If the lower substrate surrounds the buffer part, then moisture penetration route is lengthened and reliability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The moisture barrier function is merged into the lower substrate itself by folding it upward to form side walls. This eliminates the need for separate moisture barrier layers or peripheral sealing structures, as the substrate performs both structural support and moisture protection functions in an integrated manner
Solution Approach 2:
The lower substrate serves itself by forming its own protective side walls through folding. The substrate creates its own moisture barrier without requiring external components or additional manufacturing steps for separate sealing structures, making the manufacturing process relatively simple while achieving improved moisture resistance
3Reliability
If a separate shielding work for the bus bar is performed, then the bus bar is protected, but the manufacturing process becomes more complex
Solution Approach 1:
The lower substrate is given multiple functions: it supports the solar cells, forms protective side walls to prevent moisture penetration, and shields the bus bar through its folded structure. This multi-functionality eliminates the need for separate shielding components, reducing device complexity while maintaining protection of the bus bar
Solution Approach 2:
The shielding function for the bus bar is merged into the folded structure of the lower substrate. The side wall formed by folding the substrate naturally covers and protects the bus bar, combining the shielding function with the moisture barrier function in a single structural element
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 design enhances the reliability of solar cell modules by reducing moisture penetration and eliminating the need for separate bus bar shielding, leading to improved durability and streamlined production.
Implementation Method 1
if the lower substrate has a color, the lower substrate may shield the bus bar on the solar cell panel
Implementation Method 2
A solar cell module to convert light energy into electrical energy through photoelectric conversion effect
Data Source
AI summary
A solar cell module includes a solar cell panel comprising a lower substrate and a plurality of solar cells on the lower substrate; a protective substrate on the solar cell panel; and a buffer part between the solar cell panel and the protective substrate, wherein the lower substrate includes a first lower substrate supporting the solar cell and a second lower substrate disposed along a lateral side of the buffer part.