Photovoltaic Module Encapsulation Using Aligned Fast-Curing Fill Structures
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Solution Overview
Problem
Existing photovoltaic modules face issues such as glue separation between packaging structures, poor stability, and inefficient encapsulation processes, leading to increased labor intensity and reduced encapsulation efficiency.
Innovation Solution
A photovoltaic module design featuring a first and second encapsulating adhesive film with aligned holes and filling structures made of fast-curing material, along with protrusion structures, to facilitate rapid positioning and prevent slip during encapsulation, enhancing stability and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional encapsulating adhesive films are used without filling structures, then the structure is simpler, but glue separation occurs between packaging structures and solar cells leading to poor stability
Solution Approach 1:
The encapsulating adhesive film is segmented into multiple layers (first encapsulating adhesive film and second encapsulating adhesive film) with filling structures positioned at specific locations. This segmentation allows each layer to perform specific functions: the first film provides initial encapsulation, the filling structures prevent relative slip, and the second film provides additional protection, collectively preventing glue separation while maintaining structural clarity.
Solution Approach 2:
The filling structures are pre-positioned within the encapsulating adhesive film assembly before the encapsulation process. These structures are preliminarily arranged to align with corresponding holes in the solar cell holder, ensuring that when encapsulation occurs, the relative slip is immediately prevented without requiring additional adjustment or complex mechanisms during assembly.
2Productivity
If traditional encapsulation processes are used without positioning structures, then the process is simpler, but rapid positioning of solar cells cannot be achieved increasing labor intensity
Solution Approach 1:
The filling structures and protrusion structures on the solar cell holder provide self-positioning functionality during encapsulation. When the encapsulating adhesive film is applied, these structures automatically guide and position the solar cells through mechanical interlocking (filling structures fitting into holes, protrusion structures engaging with corresponding features), eliminating the need for external positioning devices or manual adjustment, thereby reducing labor intensity while improving encapsulation efficiency.
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 improves the stability and yield of photovoltaic modules by preventing relative slip between adhesive films and cell strings, ensuring proper positioning, and extending the service life through enhanced adhesion and snap-in connections.
Implementation Method 1
at least one filling structure, each filling structure of the at least one filling structure fills a respective first hole and a respective second hole, wherein the at least one filling structure includes a material having a crosslinking curing speed that is faster than a crosslinking curing speed of a material in the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material in the second encapsulating adhesive film
Data Source
AI summary
A photovoltaic module and a method for manufacturing the same are provided. The photovoltaic module includes a plurality of cell strings; a first encapsulating adhesive film and a second encapsulating adhesive film, where the photovoltaic module has a central region and a peripheral region, where the first encapsulating adhesive film defines at least one first hole and the second encapsulating adhesive film defines at least one second hole, and each first hole directly faces a corresponding second hole; and at least one filling structure, where the at least one filling structure includes a material having a crosslinking curing speed that is faster than a crosslinking curing speed of a material in the first encapsulating adhesive film and is faster than a crosslinking curing speed of a material in the second encapsulating adhesive film.