Specialized Encapsulation Techniques for Thin Film Solar Cells

Solar cell encapsulation composite film and low-temperature encapsulation method using the same Technical field: A solar cell encapsulation composite film and a low-temperature encapsulation method using the same, comprising: a heat seal layer, the material of the heat seal layer comprises a first polyolefin elastomer (POE), wherein the chemical structure of the first polyolefin elastomer has a first main carbon chain and a plurality of first side chains connected to the first main carbon chain, and the plurality of first side chains are each independently an alkyl group having a carbon number of 2 to 8; the melting point of the first polyolefin elastomer is greater than or equal to 60° C. and less than or equal to 120° C.; a first adhesive layer, the first adhesive layer is disposed on the surface of the heat seal layer; an oxygen barrier layer, the oxygen barrier layer is disposed on the surface of the first adhesive layer, wherein the material of the oxygen barrier layer comprises an ethylene/vinyl alcohol copolymer (ethylene vinyl alcohol.

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Encapsulating film for high-efficiency photovoltaic cells that provides protection against environmental degradation and oxidation to improve component lifespan. The film has a controlled thickness of 0.2-0.8 mm to balance light transmittance and adhesion force. It uses a specific cellulose derivative with a viscosity of 80-3000 mPa·s to provide both barrier properties against water vapor and aging resistance.

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Film for encapsulating solar cells in photovoltaic modules that provides improved electrical resistance, moisture barrier, and chemical stability compared to conventional encapsulant films. The film contains a functionalized polyolefin polymer like propylene copolymers, terpolymers, or ethylene terpolymers with polar groups derived from olefin monomers like hydroxyl, carboxylic acid, or esterified olefins. The functional groups enhance resistance to moisture and chemical degradation compared to unmodified polyolefins. The film can be prepared by extrusion or compression molding processes. The functionalized polyolefin encapsulant film provides superior electrical properties, moisture barrier, and chemical stability for solar cell encapsulation in photovoltaic modules.

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Photovoltaic module packaging method, an organic silicone film and a packaged photovoltaic component, which addresses the limitations of conventional encapsulation films by integrating a silicone film with pre-press grooves that serve as a bonding adhesive. The silicone film incorporates a specialized surface with strategically arranged grooves for enhanced bonding strength, while the pre-press grooves enable precise alignment of the photovoltaic cells and light-transmitting front plate. This integrated approach enables improved light transmission, water vapor barrier performance, resistivity, and aging resistance compared to conventional encapsulation films.

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Encapsulant film for solar cells with improved backside protection and reduced encapsulant thickness. The film features a region with a different thickness compared to adjacent regions, specifically designed to fill gaps between backplate and welding strip interfaces. This design enables complete encapsulant coverage between the backplate and solar cells, while maintaining structural integrity and preventing potential degradation mechanisms like water vapor infiltration and sodium ions. The film is fabricated with a specific thickness profile that optimizes encapsulant distribution between the backplate and solar cells, resulting in enhanced yield and performance.

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A thin film encapsulation structure for solar cells that prevents water and oxygen erosion through enhanced moisture barrier properties. The structure comprises an encapsulation layer made by alternating deposition of inorganic and organic materials, resulting in a compact and dense film that significantly reduces water and oxygen permeability. This architecture improves the long-term durability of solar cells in humid environments by preventing water ingress and maintaining cell performance.

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Packaging method for ultra-thin flexible solar cells that can withstand extreme environments like high altitudes, cold temperatures, salt, humidity, and wind without failing. The packaging involves laminating films, adhesive, and foam around the solar cell in a specific sequence and then heat laminating at high temperature. The lamination layers include a high-transmittance fluoropolymer film, an adhesive film, the solar cell, another adhesive film, and a foam board. This provides environmental protection, shock absorption, and thermal insulation to prevent cell damage in harsh conditions.

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A high-reflection adhesive film for encapsulating photovoltaic cells that achieves improved power generation efficiency and thermal management through enhanced light absorption properties. The film combines a black structural design with high reflectivity in the visible and infrared spectrum, enabling transparent cell encapsulation while maintaining consistent front and back appearance. This innovative approach addresses the common issues of low initial power, high operating temperature, and short service life associated with traditional black coatings, while maintaining the appearance and light-pollution avoidance requirements of photovoltaic modules.

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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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Polyolefin photovoltaic encapsulation film and preparation method for photovoltaic cells, comprising a polyolefin adhesive film, a core layer polyolefin adhesive film, and a lower layer polyolefin adhesive film compounded sequentially from top to bottom. The film is prepared through a process that combines the polyolefin adhesive films in the desired sequential order, with specific additives such as UV stabilizers and heat stabilizers. The sequential layering ensures optimal performance characteristics including high transparency, excellent thermal stability, and excellent light transmission properties.

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A solar cell module that enables direct use of individual solar cells as power sources. The module comprises a single solar cell, an encapsulation film, and a solar cell module structure. The encapsulation film provides electrical isolation between the solar cell and the module structure, while the module structure enables direct connection between the solar cell and the encapsulation film. This design eliminates the need for series and parallel connections between individual solar cells, enabling a single solar cell to serve as a power source in a solar cell module.

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Solar cell with improved moisture stability and long-term stability through a novel encapsulation layer that enhances air gel properties. The encapsulation layer, a silica-based air gel film, is applied between the optoelectronic device and substrate, providing a transparent barrier against moisture while maintaining optical transparency. The air gel film's unique properties, including its high porosity and thermal insulation, enable effective protection against environmental factors without compromising device performance. This approach enables solar cells that can operate effectively in a wide range of environmental conditions, particularly in applications requiring long-term stability.

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High-frequency magnetron sputtering method for producing cobelite thin films with controlled crystal structure and orientation, enabling enhanced open-circuit voltage and current density in solar cells. The method employs RF magnetron sputtering to deposit cobelite on a substrate, followed by deposition of a light-absorbing layer and subsequent solar cell assembly. The process specifically targets cobelite's hexagonal structure and (110) plane orientation, which are critical for achieving optimal photovoltaic performance. The cobelite thin film serves as an effective absorption layer in solar cells, with improved Voc, Jsc, FF, and PCE compared to conventional materials.

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Flexible solar thin film battery packaging solution that addresses the challenges of waterproofing and structural integrity in thin-film solar cells. The packaging structure employs a transparent ETFE film as the primary encapsulation material, with a specialized POE-based adhesive bonding system that ensures reliable lamination and interlayer alignment. The solution features a unique square groove tooling design that enables efficient lamination of the solar cell package while preventing layer dislocations. This innovative approach enables high-performance, flexible solar cell packaging with superior light transmission and efficiency compared to conventional multilayer encapsulation methods.

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A solar cell assembly that enables efficient and compact power generation through novel encapsulation and manufacturing techniques. The assembly comprises a single solar cell, an encapsulation film, and a solar cell module, where the encapsulation film is integrated with the solar cell in a single package. The encapsulation film, comprising a photovoltaic material and a transparent polymer matrix, is fabricated using a novel cross-linking process that enables efficient encapsulation of the solar cell while maintaining its optical and electrical properties. The encapsulation film is then integrated into the solar cell module through a simple and reliable manufacturing process, eliminating the need for separate battery assembly steps.

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Solar cell photovoltaic module with enhanced packaging performance through a novel encapsulation layer. The module features a second epoxy resin encapsulation layer that enhances light transmission while maintaining thermal stability. The encapsulation layer is applied after component trimming to eliminate optical interference from the surface finishes. This innovative approach enables high-performance solar cells in complex geometries while maintaining optical 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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A method for manufacturing thin-film solar cells that enables selective transmission, reflection, and color control through a single processing step. The method integrates color control encapsulant with the solar cell layer through a face seal process, where the encapsulant is applied to the solar cell surface and then encapsulated in the solar cell. This integrated approach eliminates the need for separate color control layers, enabling efficient implementation of color management in thin-film solar cells. The method also enables selective transmission and reflection through the encapsulant, while maintaining the solar cell's performance characteristics.

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Photovoltaic devices with enhanced environmental durability through novel encapsulation layers. The devices employ a fully-formed photovoltaic module structure with integrated barrier coatings that prevent moisture and oxygen ingress through their thickness. The coatings are applied through a controlled masking process, ensuring precise coverage of critical electrical connections. This approach replaces traditional glass and polymer encapsulants, enabling higher efficiency thin-film cell technologies while maintaining reliability and environmental sensitivity.

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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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