Solar Cell Module Encapsulation Without Lamination Cracks

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Solution Overview

Problem

Current solar cell modules face challenges in reducing the thickness of the encapsulant material layer and the distance between the back plate and the solar cell while maintaining sufficient yield strength and minimizing power loss, as well as avoiding direct contact between the welding strip and the glass to improve anti-PID performance.

Innovation Solution

A manufacturing method that involves providing a solar cell string, fabricating a back plate with a reserved hole, arranging the solar cell string on a front plate with a glass glaze, injecting encapsulant material through the hole, and curing it without a lamination process, which reduces the encapsulant material usage and distance between the plates, and uses glass glaze to prevent direct contact and enhance protection of the welding strip.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If the encapsulant material layer thickness is reduced, then the distance between the back plate and solar cell is reduced, but the yield strength may be insufficient

Engineering Contradiction:

Improveencapsulant material layer thicknessVSAvoidyield strength

Core Design Contradiction:

Length of stationary objectVSStrength

Solution Approach 1:

The patent employs a thin film structure where the encapsulant material is applied as a coating rather than a thick layer, achieving both reduced thickness and maintained strength through the film's inherent properties and the glass glaze reinforcement

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure by combining the encapsulant material with glass glaze applied on the back plate surface, forming a reinforced composite layer that provides both mechanical strength and electrical isolation functionality

Inventive Principle:

Principle #40Composite materials

2Length of stationary object

If the distance between the back plate and solar cell is reduced, then light extraction efficiency is improved, but the risk of direct contact between welding strip and glass increases

Engineering Contradiction:

Improvedistance between back plate and solar cellVSAvoiddirect contact between welding strip and glass

Core Design Contradiction:

Length of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces glass glaze as an intermediary substance applied on the back plate surface, which acts as a barrier between the welding strip and the glass, preventing direct contact and the associated harmful effects while maintaining the reduced distance configuration

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The glass glaze layer serves as a sacrificial or protective coating that can be applied thinly and provides the necessary isolation function without requiring thick encapsulant material, achieving cost-effective protection

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If the encapsulant material usage is reduced, then cost is reduced, but the protection of the welding strip may be insufficient

Engineering Contradiction:

Improveencapsulant material usageVSAvoidprotection of welding strip

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent transitions from bulk encapsulant material to a thin film application, where the encapsulant is deposited as a coating that provides adequate protection with minimal material consumption, achieving both cost reduction and maintained protection functionality

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite protective system combining encapsulant material with glass glaze, where the two materials work together to provide welding strip protection with reduced total material usage compared to traditional thick encapsulant alone

Inventive Principle:

Principle #40Composite materials

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 method reduces the amount of encapsulant material used, minimizes defects in the solar cell module, improves light reflection, and enhances anti-PID performance by ensuring the welding strip is protected and reducing sodium ion influence, while maintaining the yield strength and power efficiency of the solar cell module.

Implementation Method 1

improve light extraction efficiency

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

curing the encapsulant material

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS20230275171A1Solar cell module and manufacturing method thereof

Publication Date: 2023.08.31 JA SOLAR TECH YANGZHOU

AI summary

An embodiment of the present disclosure provides a manufacturing method of a solar cell module and a solar cell module. The manufacturing method of a solar cell module includes: providing a solar cell string; fabricating a back plate, a reserved hole being opened in the back plate; providing a front plate; arranging the solar cell string on the front plate; injecting an encapsulant material; and curing the encapsulant material, to obtain the solar cell module. The solar cell module is manufactured by directly curing the injected encapsulant material and no lamination process is performed, which can avoid defects such as hidden cracks of solar cells and breakage of the welding strip caused by the lamination process, which can reduce an amount of the encapsulant material used, reduce a distance between the back plate and the solar cell string and improve the energy conversion efficiency.