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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A thin film packaging device for solar cells that prevents water vapor diffusion through a segmented organic and inorganic encapsulation structure. The device comprises a base substrate, an organic encapsulation layer with multiple unit blocks, and an inorganic encapsulation layer with a segmented structure. The organic encapsulation layer features a segmented structure with multiple unit blocks, while the inorganic encapsulation layer includes a segmented structure with separate inorganic and organic layers. This segmented design prevents water vapor diffusion through the encapsulation layers, while maintaining structural integrity.

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Flexible solar panel encapsulation film with enhanced optical properties and durability. The film comprises a polyester substrate with a frosted surface layer and a lower surface coated with a corona-treated adhesive layer. The corona treatment process provides a moisture-resistant and UV-stable interface between the film and the solar cell, while maintaining the film's optical properties. This film enables high-efficiency solar panels with improved weather resistance and mechanical strength, while maintaining the structural integrity of the solar cell.

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A method for producing an organic-inorganic hybrid encapsulating membrane for solar cells that enhances water stability and long-term durability without compromising device performance. The method employs a hybrid encapsulating film comprising multiple organic-inorganic layers, where each layer is deposited through chemical vapor deposition (CVD) and atomic layer deposition (ALD) processes. The film achieves superior moisture resistance through a cross-process approach that integrates the deposition of multiple organic and inorganic layers, with each layer optimized for its specific function. The film's uniform thickness and optimized composition enable reliable moisture barrier performance while maintaining device integrity.

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Thin film solar cell with enhanced light absorption through a novel light trapping structure. The cell features a glass substrate with a Ti back electrode layer, followed by a CdS light absorbing layer, a ZnO buffer layer, an intrinsic ZnO window layer, and a transparent ZnO electrode layer. The light absorption layer comprises a patterned array of convex structures that provide efficient light trapping. This structure is created through laser scribing of the light absorbing layer after the Ti back electrode layer. The convex structures form a series of parallel channels that facilitate efficient light collection and transport. The ZnO window layer and electrode layer provide electrical isolation and conductivity, respectively. The cell achieves superior light absorption compared to conventional solar cells due to the optimized light trapping structure.

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A solar cell packaging component that enables efficient and reliable thin-film solar cell integration while maintaining high efficiency and performance. The component comprises a solar cell encapsulation layer, a weather-resistant barrier layer, an encapsulation layer with integrated adhesive, a solar cell chip layer, and a second encapsulation layer with integrated adhesive. The component ensures reliable bonding between the solar cell and packaging layers while maintaining high barrier properties against environmental factors.

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A solar cell module encapsulation structure that provides high light transmission and low water permeability while maintaining flexibility and durability. The encapsulation consists of a thermoplastic protective layer, a transparent water barrier layer, and an adhesive layer. The thermoplastic protective layer is applied to the front surface of the solar cell, while the transparent water barrier layer is positioned between the adhesive layer and the thermoplastic protective layer. This configuration enables the solar cell to maintain optical clarity while preventing water ingress through the transparent barrier layer.

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A laminated encapsulation film for solar cells that provides improved water vapor barrier, insulation, and moisture resistance compared to conventional films. The film has two layers: a first layer made of a material like EVA, PVB, ionomer, or polyurethane, and a second layer made of a polyolefin elastomer like POE. This film structure provides better water vapor barrier, lower moisture content, higher insulation, and reduced PID compared to single-layer films.

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Solar cell module with enhanced thermal management through a novel encapsulation design. The module comprises a back glass, a front packaging board, and a thin-film battery pack, with the battery pack positioned between the back glass and the front packaging board. The battery pack features a light-receiving surface facing the front packaging board. The module employs a specialized adhesive film between the battery pack and the front packaging board, eliminating the conventional glass-to-glass interface and its associated thermal stress. This design enables the use of glass-free packaging materials while maintaining high-quality encapsulation.

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Multilayer encapsulation film for photovoltaic modules that improves solar cell efficiency by down-converting UV photons to usable wavelengths. The film comprises at least two layers: a base encapsulation layer containing an encapsulating resin, and a second layer containing an encapsulation resin and a down-converter (such as a rare earth organometallic complex) in an amount of at least 0.0001wt%. This dual-layer design enables effective down-conversion of UV photons while maintaining electrical insulation and adhesion properties.

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Thin-film solar cell with enhanced light absorption and internal quantum efficiency. The cell features a nanostructured window layer comprising a periodic array of nano-junctions, where the nano-junctions are arranged with controlled spacing and dimensions. The nanostructure array is created through a controlled solution etching process that preserves the nanostructure while minimizing reflection losses. The cell structure integrates a metal back electrode, absorption layer, buffer layer, and window layer, with the window layer featuring the nanostructured array.

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Thin film encapsulation device for solar cells that enhances moisture barrier performance while maintaining flexibility and lightness. The device incorporates a moisture barrier wall that prevents water vapor ingress while maintaining the solar cell's electrical performance. This innovative barrier system enables reliable operation of solar cells in challenging environmental conditions.

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High reflection gain type photovoltaic packaging film to increase efficiency of double-sided solar modules. The film has an encapsulation layer for protecting the solar cells and a separate reflective layer on top. The encapsulation layer is 200-500 microns thick and made of a resin blend. The reflective layer is 5-200 microns thick and has a separate resin blend. The reflective layer reflects light back to the cells below instead of allowing it to escape through the gaps between cells. This increases the amount of light captured by the cells for higher overall module efficiency.

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Thin-film solar cell module structure and manufacturing process that enables selective removal of light absorption layers while maintaining the metal rear electrode. The process employs a substrate-incident laser to selectively remove light absorption layers and rear electrode layers through controlled laser heating, while preserving the metal rear electrode. The selective removal is achieved through precise laser wavelength selection and spatial control, enabling precise separation of the light absorption layer and rear electrode stacks. The selective removal process is performed in two laser scribing steps, with the laser operating at a wavelength that selectively targets the desired layers.

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Solar cell package composite membrane that enhances the durability and performance of solar cells through a multi-layered assembly. The membrane comprises a low iron glass substrate, an encapsulation layer of ethylene-vinyl acetate (EVA) adhesive, a solar cell sheet, a TPT composite film, and a TPT composite film under the EVA encapsulation layer. The assembly combines the benefits of transparent EVA adhesive encapsulation, solar cell sheet attachment, and TPT composite films that enhance aging, water absorption, and shock resistance.

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A sealing sheet for solar cells and solar cell modules that prevents moisture-related degradation while maintaining the encapsulant's crosslinking properties. The sealing sheet comprises a moisture-resistant encapsulant material that is integrated into the solar cell structure, eliminating the need for separate crosslinking steps. The encapsulant material provides excellent moisture protection and mechanical integrity, while maintaining its crosslinking capabilities during the manufacturing process.

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Thin-film encapsulation for optoelectronic devices that provides moisture and oxygen protection through a novel encapsulation system. The encapsulation unit comprises a thin-film encapsulant that is applied to the device surface, and a protective layer that is integrated into the encapsulant. The protective layer is formed through a process that integrates the encapsulant with a sacrificial material, creating a barrier against moisture and oxygen. This integrated approach eliminates the need for separate glass cavities while maintaining the optical properties of the device.

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Multilayer composite film for flexible solar cell encapsulation that enables high-performance packaging of solar cells while maintaining their bendability and optical properties. The film consists of a protective layer and an encapsulation layer with a gas barrier layer, where the encapsulation layer contains a base film, primer layer, and a gas barrier layer. The film is fabricated through a process that includes lamination of the protective and encapsulation layers at elevated temperatures, followed by removal of the outermost protective layer. The film's unique architecture combines the benefits of a protective layer and an encapsulation layer with a gas barrier layer, enabling effective barrier protection while maintaining the solar cell's optical properties and mechanical flexibility.

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Fluorinated polyimide film for flexible or thin-film solar cells that enhances solar cell performance through encapsulation of the light-incident surface. The film is prepared by incorporating nano-aluminum powder into the polyimide matrix, creating a self-cleaning surface that prevents light scattering and absorption. This encapsulation technology enables direct integration of the solar cell surface into the solar cell structure, bypassing conventional encapsulation methods. The film's fluorinated polyimide composition ensures excellent optical transparency, while the nano-aluminum reinforcement enhances mechanical properties and thermal stability.

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A method for manufacturing thin film solar cells through atomic layer deposition (ALD) that enables efficient production of high-efficiency solar cells with reduced processing steps. The method employs a buffer layer and front electrode layer that are sequentially deposited using ALD, with the buffer layer containing zinc oxide (ZnO) and the front electrode layer containing a metal precursor. The buffer layer is formed in a vacuum chamber while the front electrode layer is formed in a separate chamber, allowing precise control over thickness and composition. The method achieves high-efficiency solar cells with reduced processing complexity compared to traditional manufacturing processes.

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A silicon-based thin-film solar cell with integrated reflective backplane and battery package that achieves enhanced efficiency, production capacity, and cost-effectiveness through synchronized preparation of the reflective backplane and battery package. The solution employs a lamination process to encapsulate the battery package through the backplane, eliminating the need for separate deposition steps. This integrated approach enables simultaneous deposition of the reflective backplane and battery package while maintaining their independent preparation capabilities. The lamination process further enables the production of the solar cell with reduced cycle time, increased production capacity, and lower production cost compared to traditional sequential deposition methods.

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Organic thin-film solar cell with enhanced durability through a novel barrier film design. The cell incorporates a barrier film that bonds to a single-layer protective film with a UV-curable resin, simplifying manufacturing while maintaining excellent mechanical strength and barrier properties. The barrier film protects against moisture and oxygen while enabling easy end-face extraction during manufacturing. This approach enables production of solar cells with superior durability compared to conventional multi-layered protective films.

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Thin-film solar cell with a back electrode that enhances power conversion efficiency through a novel barrier layer approach. The cell employs a multi-layered barrier structure comprising alternating inorganic and organic barrier layers, where the organic barrier layer is formed through a polymeric binder material. This multi-layered barrier system provides superior moisture and humidity resistance while maintaining excellent electrical properties. The multi-layered barrier structure enables the formation of a compact, water-resistant, and weather-resistant solar cell with improved performance compared to traditional barrier layer configurations.

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A solar cell module with enhanced thermal stability through a polysiloxane encapsulating material. The material, with a storage elastic modulus of 1-300 MPa, prevents electrode breakage during temperature fluctuations. The encapsulant is formed through a controlled curing process that maintains its mechanical properties in -40°C to 85°C temperature range, enabling reliable performance under various environmental conditions.

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Flexible thin-film solar cell encapsulation method for solar cells that enables both high rigidity and weight reduction. The method involves encapsulating the solar cell in a flexible polymer matrix, which is then integrated into a flexible substrate. The polymer matrix provides excellent mechanical strength while maintaining flexibility, while the substrate ensures structural integrity during installation. This approach enables both high-performance solar cells and robust packaging solutions that can be easily integrated into various applications.

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A flexible, three-dimensional thin-film solar cell design that enables high-efficiency, low-cost production of solar panels with a cylindrical structure. The cell features a liner core with a thin film battery layer, encapsulating material, and back electrode layer, while the power generation layer, transparent conductive layer, and transparent substrate are sequentially covered to the outside. The packaging material is sleeved outside the liner core, maintaining the three-dimensional structure. The cell's unique design eliminates the need for a rigid substrate and enables direct coating of the solar cell components onto the liner core, while maintaining high efficiency and yield compared to traditional flat solar cells.

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A solar energy battery packaging film with enhanced weather resistance properties, specifically designed for photovoltaic (PV) battery applications. The film incorporates a modified polytetrafluoroethylene (PTFE) layer with fluorine-based additives, achieving superior mechanical strength, chemical resistance, and aging durability compared to conventional PTFE. This fluorinated layer provides excellent adhesion to PV components while maintaining the film's structural integrity. The film's composition enables reliable insulation, water resistance, and thermal management within the battery.

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Multilayer encapsulant film for solar cells that enhances photovoltaic performance through a novel composition. The film comprises an outer thermoplastic polymer layer, a middle interlayer, and a back layer, where the middle interlayer is specifically designed to incorporate a photovoltaic cell membrane material. The film's outer layer is a standard encapsulant, while the middle interlayer is a peroxide-based copolymer that contains a photovoltaic cell membrane material. This dual-layer structure enables improved light absorption and conversion efficiency by optimizing the photovoltaic cell membrane's interaction with the encapsulant. The peroxide-based copolymer, activated at the solar cell formation temperature, prevents degradation and maintains its light-absorbing properties throughout the manufacturing process.

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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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Encapsulation film for solar cells that enhances light conversion efficiency through light diffusion through particulate polymer particles. The film comprises a thermosetting acrylic resin encapsulated with uniform, granular polymer particles. These particles, which are uniformly blended into the resin, are specifically designed to manipulate light refraction through diffraction, thereby increasing the probability of solar cell absorption. The film maintains its optical transparency and mechanical properties after encapsulation, ensuring the solar cell remains functional while maximizing light absorption.

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Thin film solar cell packaging using a cross-linked epoxy adhesive film with enhanced thermal stability and mechanical properties. The film combines high-temperature resistance with low fluidity and excellent bonding strength, enabling continuous roll production of solar cell modules. The adhesive film contains additives that enhance light stabilization, thermal management, and mechanical durability. This innovative packaging solution addresses the challenges of traditional roll-forming techniques while maintaining the high efficiency and reliability of thin film solar cells.

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