Solar Module Insulation Film for Thin, Steel-Bonded Isolation
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Solution Overview
Problem
Existing solar cell modules face issues with insufficient insulation and adhesion between the solar cell and steel sheet, leading to potential short circuits and increased complexity and cost in production, as well as positional deviations in penetration holes affecting conductivity.
Innovation Solution
A solar cell module insulation film comprising a sealing material layer, an insulating substrate, and a polyethylene-based resin layer with a wetting tension of 36 dyne/cm or more, which improves adhesion to the steel sheet and ensures insulation, and a film thickness of 50 μm to 300 μm, allowing for reduced thickness and weight of the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thickness of the sealing material sheet is reduced to improve productivity and reduce cost, then insulation between the solar cell and steel sheet may be insufficient
Solution Approach 1:
The patent uses a composite structure consisting of a sealing material sheet and a resin film layer. The sealing material sheet provides sealing and basic insulation, while the resin film layer enhances the insulation performance between the solar cell and steel sheet. This composite approach allows the sealing material sheet to be thinner (improving productivity) while maintaining reliable insulation through the additional resin film layer.
2Reliability
If the thickness of the sealing material sheet is increased to ensure insulation, then the thickness and weight of the solar cell module increase
Solution Approach 1:
Instead of increasing the thickness of the sealing material sheet alone, the patent combines it with a resin film layer. The resin film provides additional insulation with minimal thickness increase, achieving reliable insulation while keeping the overall module thickness small. This composite structure is more efficient than simply thickening the sealing material sheet.
Solution Approach 2:
The patent changes the material parameters by introducing a resin film with specific properties (thickness of 1-100 μm, appropriate viscosity and adhesion characteristics). This parameter change allows the insulation system to achieve high performance with minimal thickness, as the resin film can be applied in thin layers that still provide effective insulation.
3Reliability
If multiple separate materials are layered to improve insulation, then the complexity of the structure and production process increases
Solution Approach 1:
The patent merges the sealing material sheet and resin film into a integrated insulation structure. The resin film is applied directly to the sealing material sheet or solar cell surface, creating a unified insulation system that performs multiple functions (sealing, insulation, protection) without requiring separate complex assembly steps. This merging reduces structural complexity while maintaining insulation performance.
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 insulation film enhances adhesion to the steel sheet, reduces module thickness and weight, improves productivity, and maintains conductivity by minimizing positional deviations in penetration holes, thereby increasing reliability and reducing production costs.
Implementation Method 1
a wetting tension of a surface of the polyethylene-based resin layer that is opposite side to the insulating substrate is 36 dyne/cm or more
Data Source
AI summary
Provided is a solar cell module insulation film disposed between a solar cell and a steel sheet in a solar cell module, the solar cell module insulation film including: a sealing material layer, an insulating substrate, and a polyethylene-based resin layer, in this order, wherein the polyethylene-based resin layer is a polyethylene film; and a wetting tension of a surface of the polyethylene-based resin layer that is opposite side to the insulating substrate is 36 dyne/cm or more.