Solar Module Cropping via Encapsulant Adhesion
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Solution Overview
Problem
Existing solar module production methods are inefficient and costly for creating modules with non-rectangular shapes, such as those for roofs with slanted edges, as they require specialized and expensive cutting techniques like laser cutting.
Innovation Solution
A method involving adhering solar cells to a sheet of encapsulant, allowing for cropping with a cutting blade to create modules of any shape, reducing costs and simplifying production by using standard cutting tools like scissors, knives, or saws, and avoiding the need for expensive laser cutting equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cutting is used to create non-rectangular solar modules, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
Solar cells are adhered to the encapsulant sheet before cropping, preparing the assembly in advance. This preliminary bonding prevents cells from shifting or breaking during the cropping process, ensuring precision without requiring expensive laser equipment. The cells are positioned and secured first, then the excess material is removed with simple cutting tools.
Solution Approach 2:
The encapsulant sheet serves as an intermediary medium that holds the solar cells in place during cropping. By bonding cells to this stable substrate first, the脆弱 solar cells are protected from direct handling and cutting forces, enabling precise cropping with inexpensive manual or mechanical cutting tools rather than requiring expensive laser equipment.
2Adaptability or versatility
If specialized solar modules are made to cover slanted edges, then adaptability is improved, but device complexity increases
Solution Approach 1:
The solar module is segmented into two functional zones: an active zone with operatively connected solar cells for power generation, and a passive zone with cropped solar cells that provide the desired shape and aesthetic appearance but are not electrically connected. This segmentation allows the module to achieve complex shapes like triangles or trapezoids without complicating the electrical system, as only the necessary cells are connected while others are simply positioned and cropped to shape.
3Manufacturing precision
If solar cells are cropped after lamination, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
Solar cells are adhered to the encapsulant sheet before cropping, preparing the assembly in advance. This preliminary bonding prevents cells from shifting or breaking during the cropping process, ensuring precision without requiring expensive laser equipment. The cells are positioned and secured first, then the excess material is removed with simple cutting tools.
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
Enables the cost-effective and efficient production of solar modules with complex shapes, such as triangular or trapezoidal forms, while maintaining the appearance and functionality of standard solar modules, using standard solar cells and reducing waste.
Implementation Method 1
at least one solar cell (3) to the first sheet of encapsulant (2) forming an adhering portion (14) between the at least one solar cell (3) and the first sheet of encapsulant (2)
Data Source
Figure 1~4
Figure 5~7
AI summary
The invention relates to a solar module (9, 17), also called a photovoltaic module, and a method for making the same. The inventive solar module (9, 17) contains at least one cropped solar cell (3, 17) the at least one cropped solar cell having been cropped along a cropping line (6), preferably by at least one cutting blade (13).