Solar Battery Module Sealing Process with Preliminary Vacuum
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Solution Overview
Problem
Existing methods for producing solar battery modules face challenges in preventing breakage of solar battery cells during the sealing process, especially when multiple cells are connected and sealed between transparent and back face panels, leading to issues like cell movement, resin flow-out, and air bubble retention.
Innovation Solution
A process involving the use of thicker sealing resin sheets between solar battery cells to distribute load evenly, combined with a controlled sealing treatment involving pressure reduction, temperature management, and crosslinking reaction optimization to prevent cell breakage and air bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If thermocompression bonding is performed under high vacuum to remove air bubbles, then air bubble retention is reduced, but solar battery cells may break due to excessive load
Solution Approach 1:
The patent applies preliminary action by performing vacuum treatment in a first heating section at a lower temperature (50-80°C) before the main thermocompression bonding in the second heating section. This preliminary vacuum removes air bubbles from the resin and laminate at a temperature where the resin has not yet softened, preventing cell breakage during the subsequent high-temperature bonding process. The cells are secured to the frame at this lower temperature, and air bubbles are evacuated before the resin becomes pliable.
Solution Approach 2:
The heating and vacuum process is segmented into two distinct sections: a first heating section operating at 50-80°C for preliminary vacuum treatment and cell securing, and a second heating section operating at 100-150°C for main thermocompression bonding. This segmentation allows air bubble removal to occur at a safe temperature for the cells, while the subsequent bonding phase occurs at higher temperatures only after the cells are secured and air bubbles are removed.
2Reliability
If resin is heated to melting point for sealing, then sealing effectiveness is improved, but resin may flow out and cells may move
Solution Approach 1:
The patent applies preliminary action by performing vacuum treatment and cell securing at a lower temperature (50-80°C) before the main thermocompression bonding. This preliminary step fixes the cells in position and removes air bubbles while the resin is still solid. Only after this preliminary securing does the process proceed to high-temperature heating (100-150°C) for effective sealing, ensuring cells are already positioned correctly and unlikely to move during the melting phase.
3Productivity
If multiple solar battery cells are sealed within a single module to improve efficiency, then productivity increases, but cell breakage risk increases due to larger load
Solution Approach 1:
The patent segments the heating and vacuum process into two distinct temperature stages with separate functions. The first stage (50-80°C) handles vacuum treatment and cell securing for multiple cells simultaneously without excessive thermal load. The second stage (100-150°C) performs the actual thermocompression bonding. This segmentation allows multiple cells to be processed together in a single module while maintaining cell integrity throughout the process.
Solution Approach 2:
The preliminary vacuum treatment and cell securing at lower temperature (50-80°C) stabilizes the positions of multiple cells within the module before the high-temperature bonding phase. This preliminary action prevents cells from moving or breaking during subsequent heating, enabling efficient multi-cell assembly while maintaining reliability.
4Object-generated harmful factors
If vacuum pressure is maintained at high level for extended period to remove air bubbles, then air bubble retention decreases, but manufacturing time increases
Solution Approach 1:
The patent performs the vacuum treatment as a preliminary action at a lower temperature (50-80°C) before the main heating phase. This preliminary vacuum efficiently removes air bubbles from the resin and laminate structure at a temperature where the resin maintains its shape. By completing air bubble removal before high-temperature bonding, the process achieves effective deaeration without requiring extended vacuum exposure during the heating phase, thus reducing total manufacturing time.
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 process effectively prevents cell breakage, resin flow-out, and air bubble retention, resulting in a durable and aesthetically pleasing solar battery module suitable for various applications, including daylighting types.
Implementation Method 1
heating the resin for melting and then cooling down it for sealing
Implementation Method 2
discharging air between the transparent panel of the light reception surface side and the back face panel
Implementation Method 3
the sealing resin is made of a crosslinkable thermoplastic resin
Data Source
AI summary
A process of producing a solar battery module having plural solar battery cells sealed by a resin between a transparent panel of the light reception surface side and a back face panel, including arranging plural solar battery cells at a prescribed interval and mutually connecting them to each other by a conductor; arranging a first sealing resin sheet between the transparent panel and the solar battery cells; arranging a second sealing resin sheet between the back face panel and the solar battery cells; arranging sealing resin sheet pieces between the solar battery cells to sandwich them in-between the first and second sealing resin sheets; discharging air between the transparent panel and the back face panel; heating the resin for melting; and cooling the resin for sealing.