Protective Encapsulation for Solar Sheets
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Solution Overview
Problem
Photovoltaic modules are sensitive to moisture and oxygen, leading to chemical and morphological degradation that shortens their performance lifetime, and existing encapsulation methods either complicate the manufacturing process or cause performance degradation.
Innovation Solution
An electrically insulating and chemically inert protective encapsulant is applied directly to photovoltaic modules, preventing reactions with air and existing encapsulation layers, allowing for encapsulation in air without degradation, using materials like vacuum-processed metals or solution-processed metal oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photovoltaic modules are encapsulated with hot melt adhesives, epoxy adhesives, or pressure/temperature sensitive adhesives, then moisture and oxygen protection is improved, but performance degradation occurs due to chemical reactions with photovoltaic layers
Solution Approach 1:
The patent introduces an electrically insulating protective layer as an intermediary between the photovoltaic module and the adhesive encapsulation. This protective layer acts as a mediator that prevents direct chemical contact between the adhesive and the organic photovoltaic layers, thereby eliminating the harmful chemical reactions while still allowing the adhesive to provide moisture and oxygen protection. The protective layer is specifically designed to be chemically inert toward both the photovoltaic materials and the adhesive materials.
Solution Approach 2:
The protective layer uses inexpensive materials such as inorganic oxides (silicon oxide, titanium oxide, zinc oxide) or organic polymers that can be applied as thin, sacrificial barriers. These materials provide temporary protection during the encapsulation process and can be disposed of or integrated into the final structure without compromising the long-term performance of the photovoltaic module.
2Reliability
If airtight packaging in inert environments is used to protect photovoltaic modules, then chemical and morphological degradation is reduced, but manufacturing complexity and costs increase
Solution Approach 1:
The protective layer is applied to the photovoltaic module before the final adhesive encapsulation step. This preliminary protective coating ensures that when standard adhesive encapsulation is performed in air, the photovoltaic layers are already protected from chemical reactions. This eliminates the need for complex inert environment packaging while maintaining protection against degradation.
Solution Approach 2:
The protective layer creates a localized inert environment directly on the photovoltaic module surface. By using chemically inert materials such as inorganic oxides or crosslinked polymers, the protective layer reproduces the protective effect of inert atmosphere packaging but in a simpler, integrated manner that allows subsequent encapsulation to proceed in normal air conditions.
3Reliability
If adhesive encapsulation is applied to protect photovoltaic modules, then moisture barrier is improved, but chemical compatibility problems arise with organic photovoltaic layers
Solution Approach 1:
The encapsulation system is segmented into two distinct functional layers: a protective layer in direct contact with the photovoltaic module that provides chemical compatibility, and an adhesive encapsulation layer that provides moisture barrier protection. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The protective layer is applied locally on the surface of the photovoltaic module where chemical contact with adhesives would occur. This localized protection ensures chemical compatibility at the critical interface between the photovoltaic layers and the adhesive, while allowing the rest of the encapsulation structure to focus on moisture barrier functions.
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 extends the lifetime of photovoltaic modules, reduces manufacturing costs, and increases the variety of encapsulation options, while maintaining performance by isolating the photovoltaic materials from moisture and oxygen.
Implementation Method 1
a protective encapsulation covering at least an active area of the photovoltaic module
Implementation Method 2
the protective encapsulation comprises a) at least one vacuum-processed material having an evaporation temperature less than or equal to 1200° C.
Implementation Method 3
b) at least one solution-processed metal oxide chosen from molybdenum oxide (MoOx), tungsten trioxide (WO3), vanadium pentoxide (V2O5), zinc oxide (ZnO), nickel oxides (NiOx), and titanium dioxide (TiO2)
Data Source
AI summary
A photovoltaic device comprising: a substrate; a photovoltaic module comprising a plurality of photovoltaic cells disposed on the substrate; a top electrode and a bottom electrode incorporated into the photovoltaic module, wherein the top electrode and the bottom electrode are at least partially exposed; and a protective encapsulation covering at least an active area of the photovoltaic module, wherein the protective encapsulation comprises a) at least one vacuum-processed material having an evaporation temperature less than or equal to 1200° C. or b) at least one solution-processed metal oxide chosen from molybdenum oxide, tungsten trioxide, vanadium pentoxide, zinc oxide, nickel oxides, and titanium dioxide.