Solar Cell Module Encapsulation for Protected Welding Strips
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Solution Overview
Problem
Current solar cell modules face challenges in reducing the amount of encapsulant material used and the distance between the back plate and the solar cell string while maintaining the yield strength and efficiency of circular welding strips, leading to increased costs and complexity in manufacturing and installation.
Innovation Solution
A manufacturing method involving the application of encapsulant material in two stages, where a first encapsulant material layer is formed on the welding strips, and a second encapsulant material layer is applied locally to key regions, including the welding strips and gaps between solar cells, to reduce material usage and ensure full protection of the welding strips during lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circular welding strip is used, then the yield strength and efficiency are improved, but the amount of encapsulant material required increases and the distance between the back plate and solar cell string increases
Solution Approach 1:
The patent applies encapsulant material selectively in different regions: a first encapsulant material layer is applied to the back surface of the welding strip, and a second encapsulant material layer is applied locally to key regions corresponding to at least one welding strip. This localized application ensures the circular welding strip is fully protected and maintains its yield strength while reducing the overall amount of encapsulant material used compared to uniform full-surface application.
2Reliability
If a circular welding strip is used, then the yield strength and efficiency are improved, but the distance between the back plate and solar cell string increases
Solution Approach 1:
The patent applies encapsulant material selectively in different regions: a first encapsulant material layer is applied to the back surface of the welding strip, and a second encapsulant material layer is applied locally to key regions corresponding to at least one welding strip. This localized application ensures the circular welding strip is fully protected and maintains its yield strength while reducing the overall amount of encapsulant material used compared to uniform full-surface application.
3Strength
If encapsulant material is applied to fully protect the welding strip, then the bonding strength between back plate and solar cell is improved, but the amount of encapsulant material used increases
Solution Approach 1:
The patent applies encapsulant material selectively in different regions: a first encapsulant material layer is applied to the back surface of the welding strip, and a second encapsulant material layer is applied locally to key regions corresponding to at least one welding strip. This localized application ensures the circular welding strip is fully protected and maintains its yield strength while reducing the overall amount of encapsulant material used compared to uniform full-surface application.
Solution Approach 2:
The patent applies encapsulant material to specific key regions rather than the entire surface. The second encapsulant material layer is applied locally to regions corresponding to at least one welding strip, providing sufficient protection and bonding strength for the critical areas without the excess material required for complete full-surface coverage.
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 approach reduces the overall encapsulant material usage, minimizes the distance between the back plate and the solar cell string, enhances the bonding strength, and improves the stability and performance of the solar cell module by ensuring the encapsulant material wraps the welding strips effectively, thereby protecting them and improving the module's reliability.
Implementation Method 1
arranging a first encapsulant material on a back surface of the welding strip, to form a first encapsulant material layer; on the back surface of the solar cell string on which the first encapsulant material layer is formed, arranging a second encapsulant material in a local region corresponding to at least one welding strip, to form a second encapsulant material layer; and laminating to form a laminate member
Data Source
Figure 1~2
Figure 3~4
AI summary
Embodiments of the present disclosure provide a solar cell module and a manufacturing method thereof. The manufacturing method includes: providing a solar cell string; arranging welding strips on a back surface of the solar cell string; arranging a first encapsulant material on a back surface of the welding strip, to form a first encapsulant material layer; on the back surface of the solar cell string, arranging a second encapsulant material in a local region corresponding to at least one welding strip, to form a second encapsulant material layer; and laminating to form a laminate member. The manufacturing method can reduce the thickness of the encapsulant film on the back surface of the solar cell, and reduce the distance between the back plate material and the solar cell string, and is capable to fully protect the welding strip.