Thin Film Solar Module Edge Insulation Groove
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Solution Overview
Problem
Thin-film solar modules face issues with leakage currents at the edge section due to incomplete electrical insulation between the front and rear electrode layers, affecting performance and requiring complex and costly manufacturing processes.
Innovation Solution
Incorporating an insulation trench below the electrical insulation groove and using a non-conductive barrier layer to enhance electrical separation between the electrode layers, with the front electrode layer removed in a one-step laser process, further isolating the rear and front electrode layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical methods using laser energy absorption are used to remove thin-film packages in the edge region, then the thin-film packages can be removed down to the substrate, but resublimated material or fragments of detached layers are deposited on the end face of the thin-film package edge, creating pathways for undesired leakage currents
Solution Approach 1:
An electrical insulation groove is introduced as an intermediary structure between the edge region and the active area. This groove, extending perpendicular to the direction of extension and adjacent to the edge region, prevents direct contact between front and back electrode layers, thereby blocking leakage current pathways while allowing the edge delamination process to proceed effectively.
Solution Approach 2:
The continuous electrode layers are segmented by creating the electrical insulation groove, which divides the structure into electrically isolated regions. This segmentation breaks the potential leakage current path by introducing a physical and electrical discontinuity between the front and back electrodes at the edge section.
2Productivity
If mechanical and/or optical methods are used for edge delamination, then the thin-film packages can be removed in the edge region, but this creates pathways for leakage currents between front and back electrodes
Solution Approach 1:
The electrical insulation groove serves as a mediator that blocks the harmful leakage currents generated by the edge delamination process. By positioning this groove adjacent to the edge region, it intercepts and prevents the formation of unwanted current pathways without interfering with the productivity of the edge processing.
Solution Approach 2:
The edge delamination process, which initially creates harmful leakage current pathways, is converted into a beneficial process by strategically positioning the electrical insulation groove. The groove utilizes the exposed substrate area created by delamination to establish effective electrical insulation, transforming the potential harm into a solution.
3Ease of manufacture
If a simple and inexpensive manufacturing process is used, then manufacturing costs are reduced, but electrical insulation between front and back electrode layers may be insufficient
Solution Approach 1:
The electrical insulation groove creates a simple yet effective segmentation of the electrode layers, providing reliable electrical insulation through a single structural feature. This approach avoids complex multi-layer insulation systems while maintaining adequate isolation between front and back electrodes.
Solution Approach 2:
The electrical insulation groove extracts and removes material from the substrate to create an insulating barrier. By taking out material rather than adding complex insulation layers, the process remains simple and cost-effective while achieving the required electrical isolation.
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 significantly reduces or prevents leakage and creepage currents, improving the solar module's performance while simplifying and reducing the manufacturing costs.
Implementation Method 1
the removal of the front electrode layer from the active layer in the electrical insulation groove can be accomplished using a laser in a single-stage ablation process
Implementation Method 2
Optical methods typically utilize laser energy absorption. Depending on the laser pulse energy and duration, the thin layers to be removed are explosively vaporized
Implementation Method 3
the thin layers to be removed are explosively vaporized, carrying away adjacent areas with them
Data Source
Figure 1a~2b
Figure 3a~4b
Figure 5a~6b
AI summary
The invention relates to a thin-film solar module comprising a substrate (1) with substrate edges and a circumferential edge section along the substrate edges; a back electrode layer (2) arranged on the substrate (1) and divided into back electrode layer strips by a plurality of back electrode layer separating grooves (21) extending along a direction of extension (E); an active layer (3) arranged on the back electrode layer (2) and divided into active layer strips by a plurality of active layer separating grooves (31) extending along the direction of extension (E); a front electrode layer (4) arranged on the active layer (3) and divided into front electrode layer strips by a plurality of front electrode layer separating grooves (41) extending along the direction of extension (E);a boundary region (5) extending perpendicular to the direction of extension (E) along the boundary section of the substrate, in which the substrate (1) is uncovered by the back electrode layer (2), the active layer (3), and the front electrode layer (4); and an electrical insulation groove (6) extending perpendicular to the direction of extension (E) adjacent to the boundary region (5). The active layer (3) is uncovered by the front electrode layer (4) in the electrical insulation groove (6).