Solar Module Backsheet Laminate Interlayer for Heat Dissipation

Solution Overview

Problem

Conventional solar module backsheets, particularly those used in high-power heterojunction cell (HJT) products, face challenges with heat dissipation and moisture resistance, leading to issues like short circuits and static discharge.

Innovation Solution

A solar module architecture that incorporates a laminate interlayer between the encapsulant and the backsheet, featuring an electrically insulating layer and a metallic barrier film, with a lateral extent less than the backsheet, to enhance heat transfer and reduce gas and liquid permeation while minimizing static buildup.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an aluminium backsheet is used to improve heat dissipation and moisture resistance, then heat transfer and moisture protection are improved, but the risk of static buildup and short circuits increases

Engineering Contradiction:

Improveheat dissipationVSAvoidshort circuit risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The backsheet is segmented into multiple functional layers: a metallic barrier film layer (providing heat dissipation and moisture resistance) and an electrically insulating layer (providing electrical insulation). This segmentation allows each layer to perform its specific function optimally without compromising overall reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backsheet uses a composite structure combining metallic material (for thermal and moisture management) with electrically insulating material (for electrical safety). This composite approach resolves the contradiction by integrating materials with complementary properties that address both heat dissipation and electrical insulation requirements simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a polymeric backsheet is used to provide electrical insulation, then static buildup risk is reduced, but heat dissipation and moisture resistance deteriorate

Engineering Contradiction:

Improvestatic discharge protectionVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The backsheet is segmented into multiple functional layers: a metallic barrier film layer (providing heat dissipation and moisture resistance) and an electrically insulating layer (providing electrical insulation). This segmentation allows each layer to perform its specific function optimally without compromising overall reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backsheet uses a composite structure combining metallic material (for thermal and moisture management) with electrically insulating material (for electrical safety). This composite approach resolves the contradiction by integrating materials with complementary properties that address both heat dissipation and electrical insulation requirements simultaneously.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a laminate interlayer with lateral extent less than the backsheet is used to reduce permeation and enhance heat transfer, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvepermeation resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The laminate interlayer is applied selectively only in the central region where solar cells are located, rather than covering the entire backsheet area. This local application provides the necessary barrier function where it is most needed (protecting solar cells from permeation and enhancing heat transfer) while minimizing the addition of complexity to the overall device structure and manufacturing process.

Inventive Principle:

Principle #3Local quality

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 configuration improves the reliability of solar modules by reducing permeation of gases and liquids, enhancing heat transfer, and minimizing static discharge risks, while also simplifying manufacturing and reducing costs.

Implementation Method 1

providing a suitable reduction in permeation of ingressive gas and/or liquid molecules into the solar module

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

providing improved heat transfer away from the solar cells

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

reduced risk of static buildup and discharge between conductive parts of the module

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS20250176281A1Solar module

Publication Date: 2025.05.29 REC SOLAR PTE LTD

AI summary

A solar module comprising: one or more solar cells having a front face and a back face, said solar cells being electrically connected to a terminal via one or more electrically conductive interconnect members, and surrounded by an encapsulant; an insulating backsheet arranged to overlay the one or more solar cells and encapsulant on a back face side of the module; and a laminate interlayer interposed between the encapsulant and the backsheet, the laminate interlayer comprising an electrically insulating layer and a metallic barrier film arranged in that order from a front face side of the module to the back face side of the module; wherein the laminate interlayer has a lateral extent less than the lateral extent of the backsheet.