Solar Battery Module Gap Filling for Sealing Stability
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Solution Overview
Problem
Solar cell modules packaged by vacuum lamination with fluorine-containing resin films often have air-containing spaces that expand due to temperature fluctuations, leading to inadequate sealing and reduced photoelectric conversion efficiency over time.
Innovation Solution
Incorporating a filling member, such as a cured resin composition, in the gaps between the barrier packaging material and the solar cell module's base plates to ensure airtight sealing, which can be unified with the seal material for improved processability and efficiency retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum lamination with fluorine-containing resin film is used to protect solar cell module, then long-term stability is improved, but air-containing space forms at end of base plate causing inadequate sealing
Solution Approach 1:
The patent applies preliminary action by extending the barrier packaging material beyond the cell area to cover the end of the base plate, and by pre-forming the packaging structure to eliminate air-containing spaces before final sealing. This prevents the formation of inadequate sealing zones at the base plate ends that would otherwise occur with conventional vacuum lamination methods.
2Reliability
If barrier packaging material is sealed at end of base plate, then sealing is improved, but air expansion due to temperature fluctuations causes peeling stress
Solution Approach 1:
The patent applies beforehand cushioning by extending the barrier packaging material beyond the cell area to create an overlap region at the base plate end. This extended region acts as a cushioning zone that absorbs expansion stress from temperature fluctuations, preventing peeling of the seal while maintaining adequate sealing quality.
3Ease of manufacture
If gap between barrier packaging material and connected body is left empty, then packaging process is simpler, but photoelectric conversion efficiency deteriorates over time
Solution Approach 1:
The patent applies merging by integrating the extended barrier packaging material with the base plate structure to eliminate gaps between the packaging material and the connected body. This unified structure maintains photoelectric conversion efficiency retention while keeping the packaging process simple, as the extension is formed as part of the barrier packaging material itself rather than as a separate component.
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 significantly enhances the photoelectric conversion efficiency retention and long-term stability of solar cell modules by preventing gas expansion and stress-related peeling, while simplifying the packaging process.
Implementation Method 1
air inside this space may expand due to fluctuations in ambient temperature
Implementation Method 2
a resin may be used to protect the entirety of a solar cell module in order to prevent leakage of electrolyte solution from the solar cell module and infiltration of moisture from the outside
Data Source
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AI summary
A solar cell module (100) includes: a barrier packaging material (13A, 13B) that is sealed by a seal (14) and encloses a connected body including one or more cells; and lead-out electrodes (11A, 11B). The solar cell module (100) includes a gap between the barrier packaging material and a periphery of the connected body in a base plate surface direction. A filling member (30) is present in at least part of the gap.