Solar Cell Module Barrier Packaging with Segmented Sealing
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Solution Overview
Problem
Dye-sensitized solar cell modules with inadequate sealing suffer from moisture infiltration, leading to reduced photoelectric conversion efficiency due to the lack of a robust barrier packaging material and improper arrangement of lead-out electrodes.
Innovation Solution
A solar cell module design featuring a barrier packaging material that encloses both electrodes, with lead-out electrodes connected using copper foil conductors and solder connectors, and a specific arrangement where the connectors are separated from the electrolyte layer to increase the seal width, preventing moisture infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional sealing structure with corrosion resistant material coating is used, then the electrode can be protected to some extent, but the sealing is inadequate and moisture can easily infiltrate through entry points, leading to reduced photoelectric conversion efficiency
Solution Approach 1:
The sealing structure is divided into multiple independent sealing layers: a first sealing layer covering the electrolyte layer, and a second sealing layer covering the lead-out electrodes and electrical connectors. This segmentation creates multiple barrier paths that prevent moisture infiltration more effectively than a single sealing layer, as each layer provides independent protection and the combined structure eliminates vulnerable entry points.
Solution Approach 2:
The sealing structure employs a nested configuration where the first sealing layer and second sealing layer are positioned at different levels and overlap to form a comprehensive barrier. The second sealing layer is arranged to cover not only the lead-out electrodes but also the electrical connectors, creating a nested protective structure that encapsulates multiple components simultaneously and prevents moisture access to critical areas.
2Device complexity
If the lead-out electrodes and electrical connectors are arranged closely together, then the device complexity is reduced, but the seal width around the electrolyte layer is insufficient, allowing moisture to reach the photoelectrode and electrolyte layer
Solution Approach 1:
The sealing arrangement transitions from a two-dimensional planar layout to a three-dimensional multi-layer configuration. The first sealing layer and second sealing layer are positioned at different vertical levels and arranged to overlap, creating a stepped or nested three-dimensional structure. This dimensional change allows the seals to cover both the electrolyte layer and lead-out electrodes/com connectors without requiring excessive horizontal separation, thus maintaining compactness while achieving adequate seal width through vertical stacking and overlapping.
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 enhances the retention rate of photoelectric conversion efficiency by providing a robust barrier against moisture and optimizing the electrical connections within the module, leading to improved durability and performance.
Implementation Method 1
at least one barrier packaging material that encloses the one or more photoelectric conversion cells
Implementation Method 2
the first electrical connector and the second electrical connector each contain solder, a conductor of the first lead-out electrode and a conductor of the second lead-out electrode are each a copper foil
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 electrical connectors (12A, 12B). The electrical connectors (12A, 12B) are separated from the functional layer in a base plate surface direction. The barrier packaging material (13A, 13B) includes lead-out electrode exposing parts (16A, 16B) in an outer surface aligned with the base plate surface direction. These lead-out electrode exposing parts (16A, 16B) are sealed by an exposing part seal (15). The lead-out electrode exposing parts (16A, 16B) and the electrical connectors (12A, 12B) are separated in the base plate surface direction.