Tandem Solar Cell Sealing Structure for Lightweight Flat Panels
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Solution Overview
Problem
Tandem type solar cells face challenges in reducing weight while maintaining power generation efficiency, as thinning can lead to surface unevenness and decreased efficiency due to inadequate configurations of sealing and protective members.
Innovation Solution
The implementation of a specific layer structure and manufacturing method for tandem type solar cells, including a first and second sealing layer, a third sealing layer, and a protective member, with controlled thicknesses to ensure efficient sealing and protection without compromising efficiency, using a fluorine-based resin for the sealing layers and a glass substrate for the top solar cell panel, and a silicon-based substrate for the bottom solar cell panel, with a heating step to integrate the layers and ensure continuity and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the tandem type solar cell is thinned to reduce weight, then weight is reduced, but surface unevenness occurs which reduces power generation efficiency
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness of sealing layers (first sealing layer: 50-400 μm, second sealing layer: 30-400 μm, third sealing layer: 50-400 μm) and protective members to achieve the optimal balance between weight reduction and surface flatness. By adjusting these dimensional parameters, the solar cell can be thinned while preventing surface unevenness that would occur with conventional thinner designs.
Solution Approach 2:
The patent uses composite materials strategy by combining multiple sealing layers made of fluorine-based resins with different thicknesses and properties, along with protective members, to create a layered structure that provides both weight reduction and surface flatness. The composite structure of multiple sealing layers with specific thickness ranges allows the solar cell to achieve lightweight design while maintaining manufacturing precision.
2Weight of moving object
If the sealing member and protective member configurations are improved to reduce weight, then weight is reduced, but power generation efficiency may be compromised
Solution Approach 1:
The patent resolves this contradiction by changing the thickness parameters of sealing layers and protective members to specific ranges (first sealing layer: 50-400 μm, second sealing layer: 30-400 μm, third sealing layer: 50-400 μm, first protective member: 25-200 μm). These optimized parameters ensure adequate sealing and protection functions while minimizing weight, thereby maintaining power generation efficiency without compromise.
Solution Approach 2:
The patent applies local quality by assigning different thickness values to different sealing layers based on their specific functional requirements. The second sealing layer (between solar cell panels) has a thinner range (30-400 μm) compared to the first and third sealing layers (50-400 μm each), optimizing the balance between weight reduction and sealing effectiveness at different locations within the solar cell structure.
3Reliability
If multiple sealing layers are added to prevent wrinkles and deficits, then sealing reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the sealing function into three distinct sealing layers (first, second, and third sealing layers) with specific thickness ranges, each serving particular sealing requirements. This segmented approach improves sealing reliability by addressing different sealing needs at various locations, while the modular nature of the segmentation keeps the structure manageable and not excessively complex.
Solution Approach 2:
The patent implements multi-functionality by designing the sealing layers and protective members to simultaneously perform multiple functions: sealing, protection, weight reduction, and surface flatness maintenance. The fluorine-based resin sealing layers provide both sealing and structural support, while the protective members offer both protection and contribute to surface flatness, thereby improving reliability without proportionally increasing complexity.
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 allows for the creation of a lightweight tandem type solar cell with high efficiency by preventing wrinkles and deficits in the sealing layers, ensuring reliable insulation and electrical insulation between the solar cell panels, and maintaining strength against thermal stress.
Implementation Method 1
a heating step to integrate the layers and ensure continuity and insulation
Data Source
AI summary
A solar cell of an embodiment includes a first solar cell panel, a second solar cell panel, a first sealing layer, a second sealing layer, a third sealing layer, and a first protective member. A thickness of the first sealing layer is 50 μm or more and 400 μm or less. A thickness of the second sealing layer is 30 μm or more and 400 μm or less. A thickness of the third sealing layer is 50 μm or more and 400 μm or less. A thickness of the first protective member is 25 μm or more and 200 μm or less. A thickness of the solar cell is 350 μm or more and 1140 μm or less at a portion at which the first solar cell panel and the second solar cell panel overlap each other.