Solar Cell Module Sealing with Crosslinkable Adhesive
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Solution Overview
Problem
Dye-sensitized solar cell modules face challenges in maintaining photoelectric conversion efficiency due to inadequate sealing, leading to moisture infiltration and reduced efficiency retention, especially when the sealing width is reduced to minimize the sealing cross-sectional area.
Innovation Solution
A solar cell module design that uses a barrier packaging material sealed with a cured product of a crosslinkable adhesive composition, filling the gap between the conductor and the packaging material, and employing conductive pressure-sensitive adhesive connectors to ensure tight sealing and high efficiency retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the thickness of the seal member is reduced to reduce the sealing cross-sectional area, then the sealing cross-sectional area is reduced, but a gap at the step section with a film formed due to the thickness of the lead material cannot be adequately filled by the seal member, and thus a void is formed, and close adherence between a lead-out electrode and a moisture-proof film is inadequate
Solution Approach 1:
The patent changes the material parameters of the seal member by using a two-layer structure with different resin materials. The first layer has high fluidity to fill gaps, while the second layer provides structural support. This parameter change allows the seal member to adequately fill the gap at the step section without increasing the overall sealing cross-sectional area excessively.
Solution Approach 2:
The patent employs a composite seal member consisting of two different resin materials stacked together. The first resin material (with high fluidity) and the second resin material (with different viscosity) work together to simultaneously achieve gap filling and maintain structural integrity, resolving the contradiction between reducing seal thickness and ensuring reliable sealing.
2Reliability
If the seal member sticks out to a certain degree to avoid the formation of gaps, then gap formation is avoided, but the sealing cross-sectional area at that part becomes wider by an amount corresponding to the thickness of the seal member
Solution Approach 1:
The patent applies local quality by making different parts of the seal member have different properties. The first layer is designed with high fluidity to locally fill gaps at the step section, while the second layer provides overall structural support. This localized differentiation allows the seal to achieve reliable sealing without excessive sticking out.
3Area of stationary object
If sealing width is reduced to improve the area fraction of an electricity generating part in a solar cell module, then the area fraction of electricity generating part is improved, but it is necessary to reduce sealing cross-sectional area to inhibit infiltration of moisture and the like and maintain reliability
Solution Approach 1:
The patent changes the material parameters of the seal member to achieve high sealing performance with reduced cross-sectional area. By selecting resin materials with appropriate fluidity and viscosity characteristics, the seal member can provide effective moisture barrier protection while occupying minimal space.
Solution Approach 2:
The composite seal member structure allows for reduced sealing cross-sectional area while maintaining reliability. The two-layer design with different resin properties enables effective sealing in a more compact form, thereby preserving more area for electricity generation.
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 effectively reduces the sealing cross-sectional area while preventing moisture infiltration, maintaining high photoelectric conversion efficiency and improving production efficiency by using a photocurable resin composition for the adhesive.
Implementation Method 1
a gap between each of the conductors and the barrier packaging material is filled by a cured product of a crosslinkable adhesive composition
Implementation Method 2
each of the first electrical connector and the second electrical connector includes conductive pressure-sensitive adhesive
Implementation Method 3
using a photocurable resin composition for the adhesive
Data Source
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AI summary
A solar cell module (100) includes: one or more cells that are enclosed by a barrier packaging material (13A, 13B) and that include first and second base plates (3, 7) and a functional layer; and first and second lead-out electrodes (11A, 11B) that are respectively connected to electrodes (2, 6) disposed at the sides of the respective base plates (3, 7) via first and second electrical connectors (12A, 12B). The lead-out electrodes (11A, 11B) each include a conductor. The barrier packaging material (13A, 13B) includes at least one seal (14) that extends either or both of the lead-out electrodes (11A, 11B) from the solar cell module (100). Gaps between the conductors of the lead-out electrodes (11A, 11B) and the barrier packaging material (13A, 13B) at the at least one seal (14) are filled by a cured product of a crosslinkable adhesive composition (15).