研究目的
To develop a new low cost high durability module encapsulation technology to reduce LCOE (Levelized Cost of Electricity) by improving reliability and reducing manufacturing costs.
研究成果
The new module architecture and encapsulation technology offer significant benefits including extreme robustness to moisture degradation and UV exposure, reduced manufacturing cost and time, and smaller manufacturing tool footprint. The technology is adaptable to both thin film and c-Si module architectures, promising to significantly lower the LCOE of solar modules.
研究不足
The research is in the prototype stage, and further testing is needed to validate the technology's reliability and durability under various environmental conditions. The scalability of the manufacturing process to industrial levels also requires verification.
1：Experimental Design and Method Selection:
The research involves developing a novel module architecture and encapsulation technology that replaces the traditional vacuum lamination process with a streamlined manufacturing process. This includes the use of a two-component perimeter seal and a low-cost, desiccated thermoplastic interlayer applied via hot melt injection.
2：Sample Selection and Data Sources:
Prototype modules are fabricated without semiconductor films or cells for testing. Moisture-indicating materials such as cobalt chloride (CoCl2) are used to track moisture penetration.
3：List of Experimental Equipment and Materials:
Equipment includes heated platen press systems (Graco Therm-O-Flow), precision metering systems (Graco PGM), and mechanical press tooling. Materials include silicone, poly iso-butylene (PIB) polymer, and polyolefin based thermoplastic with desiccant.
4：Experimental Procedures and Operational Workflow:
The edge seal application tool deposits PIB and silicone materials on the cover glass substrate. The interlayer is deposited on the back glass. The two glass plates are then joined and pressed.
5：Data Analysis Methods:
Samples undergo stress testing including 'damp heat' and 'humidity freeze' tests to determine moisture ingress rates and durability benefits.
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