Solar Module Insulating Adhesive for Frameless Carrier Support
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Solution Overview
Problem
Solar modules experience potential-induced performance degradation due to high electrical field strengths between module carriers and photovoltaic layer structures, leading to corrosion and delamination, especially when grounded, which existing solutions attempt to mitigate with additional electrical components or inefficient inverters.
Innovation Solution
A solar module design featuring electrically highly insulating adhesive layers for attaching metallic module carriers to the substrate, which reduces electrical field strengths and prevents ion migration, thereby minimizing performance degradation without the need for additional electrical components or complex inverter adaptations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If module carriers are grounded to provide mechanical reinforcement and mounting, then mechanical strength and ease of mounting are improved, but electrical field strengths cause ion migration and performance degradation
Solution Approach 1:
An electrically insulating adhesive layer is introduced as an intermediary between the metallic module carrier and the photovoltaic layer structure. This adhesive layer mechanically bonds the carrier to the module while electrically isolating it, preventing ion migration and potential-induced performance degradation while maintaining the mechanical reinforcement function
Solution Approach 2:
The adhesive layer is applied specifically at the interface between the module carrier and the photovoltaic structure, providing localized electrical insulation exactly where the harmful electrical field interaction occurs, while allowing the rest of the module carrier to maintain its mechanical function
2Reliability
If additional electrical components are added to mitigate potential-induced degradation, then electrical stability is improved, but device complexity increases
Solution Approach 1:
The electrically insulating adhesive layer provides the electrical isolation function as an inherent property of the bonding material itself, eliminating the need for separate electrical isolation components. The adhesive simultaneously performs mechanical bonding and electrical insulation functions
Solution Approach 2:
The adhesive layer serves multiple functions simultaneously: mechanical bonding between carrier and substrate, electrical insulation to prevent ion migration, and potential spacing function. This multi-functionality eliminates the need for additional dedicated components
3Weight of moving object
If frameless module construction is used to reduce weight and cost, then weight and manufacturing cost are reduced, but mechanical reinforcement is compromised
Solution Approach 1:
The electrically insulating adhesive layer acts as a thin film that provides both mechanical bonding and electrical insulation functions, enabling frameless construction while maintaining necessary mechanical reinforcement through the adhesive-bonded module carrier structure
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 use of highly insulating adhesives significantly reduces potential-induced performance degradation, maintaining solar module efficiency even under high voltage differences, and allows for frameless module construction with improved manufacturing simplicity and cost-effectiveness.
Implementation Method 1
the adhesive layer contains or consists of an adhesive that is electrically highly insulating, at least in the hardened state
Data Source
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AI summary
The invention relates to a solar panel (1) comprising at least one substrate (2) and a cover layer (30) between which a layer structure (23) for forming solar cells (31) is arranged, and at least one panel support (4) which is arranged on a substrate surface (3) facing away from the layer structure (23) for reinforcing and/or supporting the mounting of the solar panel (1) which has at least one adhesive surface (19) which is adhered to the substrate surface (3) by at least one adhesive layer (20). The adhesive layer (20) contains a hardened, electrically highly-insulating adhesive (35).