Solar Panel Encapsulation Technologies and Materials

A method for packaging large-area perovskite solar cells using a single-step encapsulation process. The method involves depositing a thin insulating layer on the perovskite cell's back electrode, followed by a polymer film and a backing sheet. The insulating layer is formed through magnetron sputtering or ALD, while the polymer film is applied in a sequential layering process. The cell is then melted and bonded through vacuum heating to complete the secondary packaging. This approach eliminates the need for multiple layers and provides enhanced thermal stability compared to conventional encapsulation methods.

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Flexible perovskite solar cell packaging method that enables stable operation in underwater environments. The method employs a novel encapsulation process that integrates a transparent polymer film (TPU) with a perovskite solar cell, eliminating the need for rigid substrates. The TPU film is prepared through a scraper process on a glass substrate, then dried to form a packageable film. The solar cell is encapsulated within this TPU film using a specific chemical reaction between NDC and EG, which generates a water-resistant ester. The TPU film provides excellent barrier properties against water, light, and heat, while the perovskite solar cell maintains its efficiency in the underwater environment.

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Solar cell with enhanced optical protection through a dual-layer encapsulation structure. The cell features a primary encapsulation layer that fills the space between adjacent solar cells, while a secondary encapsulation layer is positioned on top of this primary layer. This dual-layer configuration prevents water and oxygen from penetrating through the space between cells, maintaining the solar cell's optical integrity. The encapsulation materials used in both layers are specifically designed to prevent degradation of the solar cell's absorber layer.

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Highly efficient back-contacted solar cell with passivated contacts that reduces recombination and improves efficiency. The cell has interdigitated electrodes on the back contacting doped regions of opposite polarity. The doping in the regions is balanced to create the opposite polarity. This eliminates the need for complex doping steps or masks on the back. The front has lower doping compared to the back. Passivation layers on front and back further reduce recombination. The cell is manufactured by depositing a polycrystalline silicon layer on a dielectric layer, locally doping the back regions, and forming passivation layers.

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Solar cell packaging method that enhances the durability and performance of crystalline silicon solar cells through advanced encapsulation technology. The method employs polyaspartate polyurea encapsulation layers that provide superior water and oxygen barrier properties compared to conventional materials. The encapsulation layers are applied in a multi-layer structure with polyaspartate polyurea on both the front and back sides of the solar cell, ensuring complete water and oxygen protection. The encapsulation layers are then bonded to the solar cell using a specialized bonding process that incorporates mechanical retention elements. The solar cells are then encapsulated in a polyaspartate polyurea-based transparent material that maintains its integrity even under accelerated aging conditions. The encapsulation method enables the creation of solar cells with enhanced durability and service life, particularly in applications where the solar cells are exposed to outdoor environmental conditions.

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Solar module design to prevent moisture ingress and improve reliability. The solar module has an encapsulation part that houses multiple spaced apart solar cell modules. This configuration prevents direct contact between adjacent cell modules, reducing the risk of moisture ingress and corrosion. The encapsulation also provides protection against environmental factors like dust and debris. The spacing between cell modules allows for better airflow and cooling compared to stacked cells.

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Rollable solar cell module that can bend and fold without constraint on curvature radius. The module has thin front and back sheets around the solar cells, with a sealing member between them. The thinner sheets and sealing allow the module to roll and bend into tighter spaces compared to thicker conventional modules. This enables applications like rollable blinds, curved solar panels, and portable devices with more compact and flexible solar power sources. The thinner sheets and sealing also reduce weight and material usage compared to thicker modules.

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A method for encapsulating perovskite solar cells that enables stable operation in harsh environmental conditions. The encapsulation process involves applying a polyurethane hot-melt adhesive film between the perovskite solar cell and a backing layer, followed by sequential heating. The adhesive film solidifies at temperatures below 70°C, allowing it to form a stable film structure that protects the perovskite solar cell from environmental degradation. This approach eliminates the need for separate encapsulation steps and conventional adhesives, enabling reliable performance in high-humidity environments.

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Color photovoltaic module with improved color uniformity and aesthetics compared to conventional colored solar cells. The module has a stacked structure with a solar cell layer sandwiched between encapsulant layers. Between the cell and top encapsulant is a layer of porous colored fiber. This adds color without the output variation issues of colored glass. The fiber layer improves aesthetics while maintaining power generation efficiency and competitive cost. The module is manufactured by adding the fiber layer between encapsulants after the cell step.

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Manufacturing method for photovoltaic modules that improves encapsulation through controlled encapsulant thickness and bubble formation prevention. The method integrates a crosslinked polymer adhesion layer between the encapsulant and photovoltaic cell, with a separate crosslinked polymer encapsulant layer. The adhesion layer is applied before the encapsulant, allowing precise control over encapsulant thickness and bubble formation. This integrated approach enables both enhanced encapsulant performance and bubble management, while maintaining the structural integrity of the photovoltaic cell.

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A method for encapsulating individual solar cells into solar cell modules that enables rapid replacement of defective cells. The encapsulation process involves integrating a single solar cell into a module using a specialized encapsulation material, which is then assembled into a complete solar cell module. This approach eliminates the need for manual handling of individual solar cells and their assembly into modules, significantly reducing the complexity and weight of solar cell modules compared to traditional encapsulation methods.

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A photovoltaic window comprising a transparent plastic substrate with integrated photovoltaic cells and an optically coupling fluid. The window features a specially designed substrate with integrated PV cells that are diced from full-sized solar cells. The substrate is fabricated using a process that enables uniform cell placement and bonding, while the coupling fluid is engineered to optimize light transmission while minimizing internal reflection. The coupling fluid's refractive index (RI) is carefully controlled to prevent total internal reflection at the PV cell interface, ensuring maximum energy conversion efficiency.

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A coating-encapsulated thin-film solar cell that enables mass production of solar cells with improved durability and performance. The cell features a multilayer structure comprising a solar cell layer, a light scattering layer, and a paint encapsulation layer, all encapsulated by a thin film. The solar cell layer, light scattering layer, and paint encapsulation layer are arranged sequentially from top to bottom. The paint encapsulation layer provides enhanced weather resistance and aging resistance compared to traditional encapsulation methods. The coating-encapsulation architecture enables the use of a single production process for both the solar cell and encapsulation layers, significantly reducing production complexity and costs.

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Perovskite solar cells with enhanced durability and long-term stability achieved through a novel encapsulation approach. The cells employ an ultra-thin SiO2 encapsulation layer, comprising a transparent electrode, electron transport layer, perovskite photoactive layer, hole transport layer, and metal electrode, on a flexible substrate. The SiO2 layer is grown through thermal oxidation from a silicon wafer, providing a thin barrier against environmental degradation. This encapsulation architecture enables the perovskite solar cell to maintain its optical and electrical properties over extended periods, while maintaining its structural integrity.

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A method for packaging perovskite solar cells that enhances their stability and efficiency in air exposure. The method involves encapsulating the solar cells in a protective packaging material that incorporates a water-repellent and oxygen-permeable barrier. This barrier prevents water and oxygen from entering the solar cell while maintaining its air exposure environment. The encapsulation material can be a polymer or ceramic layer that provides the necessary protection while maintaining the solar cell's optical and electrical properties.

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Method for manufacturing light-transmitting flexible thin-film solar cells that improves efficiency through enhanced hole processing control. The method employs a novel post-processing step after hole formation in the solar cell's light transmission path, specifically targeting areas where holes create shunts. This targeted cleaning process ensures that only the critical regions of the solar cell's interface layers are cleaned, while maintaining the integrity of the rest of the cell structure. This approach enables the creation of high-efficiency solar cells with reduced shunt generation, thereby improving overall performance.

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A novel method for stabilizing perovskite solar cells (PSCs) through selective precursor dissolution (SPD) of the 2D perovskite layer on the underlying 3D perovskite structure. The SPD strategy involves using a solvent that selectively dissolves the 2D perovskite precursor while maintaining the high-quality 3D perovskite underlayer, thereby preventing crystallographic δ-phase formation and surface defects. This approach enables record-breaking PCEs (22.6%) with enhanced operational stability compared to conventional methods. The SPD method enables scalable production of heterojunction PSCs, which can be used for local and remote applications.

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Solar cell encapsulant with enhanced durability and moisture resistance, featuring a magnesium oxide-based encapsulant with controlled surface area. The encapsulant composition comprises 0.001 to 0.20 parts of magnesium oxide per 100 parts of ethylene-vinyl acetate copolymer, with a surface area of 50 to 200 m²/g. This composition provides excellent moisture resistance while maintaining sufficient durability and wet leakage resistance for solar cell modules.

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Solar cell with enhanced durability and performance through the use of a titanium dioxide-based porous membrane. The cell comprises a flexible plastic casing with a photovoltaic cell containing a battery housing, where the cell wall has a wide side with a transparent conductive layer made of plastic. The cell features an anode with a porous membrane that includes nanoparticles, where the membrane is in contact with the conductive layer and serves as an interface for the redox charge transfer substance. The cell also includes a cathode with a catalytic surface in close contact with the electrolyte. The porous membrane is produced through a process of sintering titanium dioxide at high temperatures, creating a durable and sintered layer that provides excellent mechanical strength and chemical inertness.

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A method for packaging solar cell modules, particularly curved solar cell modules, that simplifies the process, reduces costs, and enables automated production compared to conventional lamination techniques. The method involves fixing the panel, cell module chip, and backplane, then injecting molten adhesive between them to form an encapsulation film. This replaces the layering and lamination steps, reducing process steps and enabling automation. It also allows packaging curved components without specialized molds. The adhesive film bonds the components together.

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A method for improving the stability and efficiency of perovskite/silicon heterojunction solar cells through controlled deposition of a transparent conductive oxide (TCO) layer. The method involves depositing a thin, thermally evaporated TCO film on the silicon heterojunction cell surface, followed by deposition of gold electrodes on the TCO layer. The TCO layer serves as an insulating barrier between the silicon heterojunction and gold electrodes, while the gold electrodes facilitate efficient current collection. The TCO layer also prevents water and oxygen exposure to the perovskite material, thereby enhancing the solar cell's overall stability and efficiency.

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Sealing a solar cell module using ultrasonic bonding to prevent moisture and environmental contamination. The method integrates encapsulation, housing sealing, and bonding in a single process, employing ultrasonic waves to mechanically seal the module while maintaining encapsulant integrity. This approach enables reliable sealing of solar cells in organic or hybrid solar cells with poor thermal stability, without the need for high-temperature curing processes like laser soldering.

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Flexible crystalline Si solar cells fabricated through a novel bonding approach using commercially available thick crystalline Si solar cells. The solar cells are bonded to flexible conductive foil substrates through a metal interlayer stack, where the interlayer serves both as a bonding layer and an electrically conductive path between the solar cell and the foil substrate. This bonding approach enables the fabrication of flexible solar cells on curved surfaces without the need for traditional wafer-based processing, while maintaining high efficiency and structural integrity.

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Shingled solar cells with integrated electrical connections through non-linear edge protrusions. Each solar cell features a planar silicon structure with a front surface facing the light source, and an edge with protruding portions that serve as contact pads. The protruding edges of adjacent solar cells are connected through their backside contact pads, enabling electrical connectivity between the cells. The protrusions also serve as mechanical supports for the solar cells.

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Solar cell encapsulant that prevents degradation of electrodes through controlled hydrolysis of ethylene-vinyl acetate copolymer, enabling reliable performance of solar cells even after prolonged exposure to environmental conditions. The encapsulant is formulated with a specific ratio of ethylene-vinyl acetate copolymer to magnesium oxide, which enables stable hydrolysis of the copolymer while preventing electrolyte degradation. The encapsulant is used in solar cell modules to protect against moisture-related degradation of the solar cell's active material.

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Zero-loss high-efficiency silicon solar cell packaging method that improves power generation efficiency by eliminating structural losses in the solar panel. The method involves a two-step process: first, a fill layer with an organic-inorganic hybrid treatment or composite is applied to the solar cell surface, followed by an underlayer. The adhesive layer is then applied to the underlayer, forming a light-transmitting substrate. This substrate provides both mechanical protection and unobstructed illumination channels, significantly reducing power loss in the conventional solar cell packaging process.

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Encapsulation film for photovoltaic modules with precise cell alignment and reduced inactive gap between strings. The film features a structured surface with embossed elements that precisely define cell overlap, enabling direct bonding without intermediate string alignment. The embossed elements are created through precision embossing or molding processes, with the embossing pattern serving as a reference for cell positioning. The structured film enables precise control over cell-to-cell contact, resulting in reduced inactive gaps and improved module efficiency.

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Organic solar cells with metal nanostructures that exhibit enhanced light absorption and scattering through controlled near-field interactions. The solar cells incorporate regular two-dimensional metal nanostructures in their active layer, which are fabricated using a simple and scalable process. The nanostructures are arranged in a periodic pattern to optimize light absorption and scattering, leading to improved power conversion efficiency compared to conventional organic photovoltaic cells.

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Solar cell packaging method for improving power conversion efficiency and reliability. The method integrates solar cells into a single, hermetically sealed unit through vacuum thermocompression lamination, where transparent resin layers form a protective envelope around the solar cells. The solar cells are encapsulated in a specially formulated transparent resin that provides excellent optical and mechanical properties while maintaining the solar cell's electrical performance. The encapsulation process is performed using a vacuum thermocompression lamination system, enabling precise control over the resin thickness and composition.

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Nanowire perovskite solar cell with improved performance through a novel light absorption layer configuration. The cell incorporates a perovskite compound in the form of a one-dimensional nanowire web as a light absorption layer, replacing conventional three-dimensional perovskite morphology. The nanowire web structure enables localized exciton recombination, while the perovskite compound maintains its high photoluminescence quantum yield. This configuration addresses the interface separation issues between perovskite and hole transport materials, leading to enhanced solar cell performance.

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Solar cell encapsulant composition, solar cell module, and manufacturing method that improves efficiency and durability of solar cells by replacing traditional EVA with a novel encapsulant. The encapsulant composition contains a combination of UV stabilizers, a cross-linking agent, and a polymer matrix, which provides enhanced protection against moisture, UV degradation, and cross-linking reactions during manufacturing. This encapsulant composition enables faster, more efficient production of solar cell modules compared to traditional EVA-based encapsulants, while maintaining superior optical and mechanical properties.

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Rolling solar cell encapsulation material sheets with improved adhesion to PV lamination, achieved through a drum with a moisture content of 1000 ppm or less. The drum's low moisture content enables enhanced adhesion of the encapsulation film to the PV lamination process, particularly for films containing silane group-containing compounds. This results in improved adhesion characteristics during lamination, particularly for films containing silane group-containing compounds.

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A foldable solar cell case that integrates a PCB-based solar cell module with a compact, foldable design. The module features a printed circuit board substrate with series-connected solar cells, encapsulated in a thermoplastic polymer film, and mounted on a flexible connector. The case's outer shell houses the connector, while the inner shell accommodates the solar cells. The connector enables secure attachment of multiple solar cells through a flexible connector, allowing the case to be folded for storage. The case's folding mechanism eliminates common issues associated with traditional solar cell modules, such as oxidation and corrosion.

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A process for packaging double-sided glass crystalline silicon solar cell modules that eliminates bubble formation and cell displacement issues. The process involves laminating a flexible polyester film around the solar cells, followed by a specialized EVA film that is precisely engineered to minimize directional shrinkage and thermal expansion differences. The laminated EVA film is then cooled below 70°C in the laminator while the polyester film is evacuated, creating an optimal pressure differential that prevents cell displacement during the lamination process. This approach ensures reliable cell alignment and eliminates the common issues of bubble formation and cell separation during module assembly.

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Organic-inorganic solar cell with enhanced efficiency through a novel bonding layer. The solar cell comprises a transparent electrode layer, an organic photoactive layer, and a perovskite photoactive layer. The bonding layer is positioned between the organic photoactive layer and the perovskite photoactive layer, providing a transparent interface that enables light transfer from the organic layer to the perovskite layer. This transparent bonding layer enables efficient energy conversion while maintaining optical transparency, thereby achieving higher efficiency compared to conventional solar cells.

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A method for manufacturing small solar cell modules that enables efficient, automated assembly of interconnected solar cells. The method involves forming a substrate with a printed circuit containing the solar cell array, followed by connecting the solar cells to the substrate using a conductive tape. The solar cells are then encapsulated in a protective film layer, which is formed by injecting a thermoplastic polymer compound into the encapsulant layer. The encapsulant layer serves as a protective barrier while also enabling the conductive tape to bond directly to the solar cells. This integrated approach eliminates the traditional series-connection assembly process and simplifies the manufacturing workflow for small solar cell modules.

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A solar cell encapsulation method for solar panels that eliminates structural defects and improves mechanical stability. The method involves integrating a specialized frame with a connector system that precisely matches the solar cell's mounting requirements. The frame features projecting portions that extend downward and a border that includes both projecting and mounting surfaces. The connector system comprises mating surfaces that engage the projecting portions and border, ensuring secure attachment of the solar cells to the frame. This integrated approach eliminates the need for manual corner filing and corner alignment, while maintaining structural integrity and high panel strength.

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A method for manufacturing solar cells with local back surface field (LBSF) that achieves selective edge insulation while maintaining surface quality. The method employs an alkaline etching paste to create a textured surface on the back face, followed by an acid etching step specifically targeting the silicon layer. This selective etching enables precise edge insulation without damaging the silicon surface. The process combines the benefits of local back surface field technology with conventional edge insulation techniques, reducing manufacturing complexity and environmental impact.

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A method and system for encapsulating photovoltaic cells using a novel protective coating that enhances moisture and corrosion resistance while maintaining electrical integrity. The coating comprises a polymeric matrix with inorganic particulate matter such as mica, which provides superior barrier properties against moisture and environmental stressors compared to traditional EVA-based encapsulants. The particulate material enhances the coating's barrier performance while maintaining electrical conductivity and cell lifetimes. The coating is applied to both the front transparency and photovoltaic cells, enabling a single-step encapsulation process with improved performance characteristics compared to traditional multi-layered systems.

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