Solar Cell Unit Polymer Adhesive Layer Thermal Management
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Solution Overview
Problem
Existing solar cell units face challenges in protecting semiconductor bodies from environmental degradation and maintaining optical efficiency under high sunlight concentration, which leads to high temperatures and potential delamination issues due to the limitations of existing sealing materials and manufacturing processes.
Innovation Solution
A solar cell unit design featuring a polymer adhesive layer between the secondary optical element and the solar cell, which is transparent, UV-resistant, and temperature-stable, allowing for a non-positive connection without additional connecting means, and incorporating a metal layer for even heat distribution and adhesion promoter layers for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a polymer adhesive layer is used to connect the secondary optical element to the solar cell, then optical losses are minimized and UV resistance is improved, but the layer must withstand high temperatures up to 120°C which challenges material durability
Solution Approach 1:
The patent specifies that the polymer adhesive layer must maintain its optical and mechanical properties across a wide temperature range from -40°C to +120°C. This involves selecting or formulating polymer materials with appropriate glass transition temperatures and thermal stability parameters to ensure the adhesive layer remains transparent and structurally sound under concentrated photovoltaic operating conditions.
Solution Approach 2:
The invention employs a composite structure where the polymer adhesive layer is formulated with specific additives or cross-linked with other materials to enhance both UV resistance and temperature stability. This composite approach allows the adhesive to simultaneously achieve high optical transparency across the solar spectrum, UV resistance, and thermal stability up to 120°C.
2Reliability
If additional sealing layers are added to protect the semiconductor body, then protection against environmental influences is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The polymer adhesive layer is designed to perform multiple functions simultaneously: it provides mechanical bonding between the optical element and solar cell, acts as a sealant protecting the semiconductor body from environmental influences, maintains optical transparency for light transmission, and provides UV resistance. This multi-functionality eliminates the need for separate sealing layers and simplifies the manufacturing process.
Solution Approach 2:
The invention merges the functions of bonding, sealing, and optical transmission into a single polymer adhesive layer. By combining these previously separate functions into one integrated component, the patent reduces the number of manufacturing steps and eliminates the need for additional sealing layers while maintaining comprehensive protection of the semiconductor body.
3Loss of energy
If the polymer adhesive layer is made very thin to reduce optical losses, then optical efficiency is improved, but the connection strength and sealing reliability may be compromised
Solution Approach 1:
The patent specifies a controlled thickness range for the polymer adhesive layer that optimizes the balance between optical transparency and mechanical strength. By carefully controlling the thickness parameter within specific limits, the design minimizes optical path length and associated losses while maintaining sufficient bond strength and sealing capability to withstand thermal cycling and mechanical stresses.
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
This design reduces optical losses, enhances temperature resistance, and simplifies manufacturing by eliminating the need for additional sealing layers, while ensuring reliable protection against environmental influences and efficient heat transfer, leading to improved efficiency and durability of the solar cell units.
Implementation Method 1
the polymer adhesive layer must be highly transparent across the entire spectral range to be utilized
Implementation Method 2
in addition to high UV resistance
Implementation Method 3
the high concentration of sunlight generates temperatures of up to 120°C on the front of the solar cell
Implementation Method 4
An optical element directs the sunlight, focused by a Fresnel lens, onto the surface of the solar cell
Implementation Method 5
focused by a Fresnel lens
Implementation Method 6
a semiconductor body designed as a solar cell is arranged on a substrate
Data Source
Figure 1
Figure 1~2
Figure 3~4
AI summary
The unit (10) has conductor regions (40,45) that are formed on top of carrier (30). A wiring portion is electrically connected to the connecting terminals. The light is led to the front side of a semiconductor main portion (20) by optical element (22) except central portion of first shaped portion (25). A polymer adhesive layer is formed between the first shaped portion, front side of semiconductor main portion, second shaped portion (27) and carrier, so that optical element is connected to the semiconductor main portion and carrier in a force-locking manner.