Adhered Support Frame for Photovoltaic Panels

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Solution Overview

Problem

Existing photovoltaic (PV) panels require a secondary process for bonding a support frame using silicone-based adhesives, which is time-consuming and costly, and involves lengthy curing times, doubling capital expenditure and increasing manufacturing time.

Innovation Solution

A distributed support frame is adhered to the PV module during the lamination process, using an adhesive layer between the PV module and support members, allowing simultaneous curing with the encapsulant to eliminate secondary bonding operations and reduce manufacturing time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a secondary bonding process using silicone-based adhesives is used to attach the support frame, then the bonding strength and stability are improved, but the manufacturing time and capital expenditure are doubled

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the support frame attachment process with the lamination process by integrating the support frame into the laminate structure itself. The support frame is formed as part of the layered construction during the lamination process, eliminating the need for a separate secondary bonding operation. This combines two previously distinct processes (lamination and frame attachment) into one unified process, thereby reducing manufacturing time while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support frame is prepared and positioned in advance as part of the laminate assembly before the final curing process. By incorporating the support frame structure into the laminate layers during the lamination preparation stage, the frame is already in place and properly positioned before the encapsulant is applied and cured, eliminating the need for post-lamination attachment operations.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If silicone-based adhesives are used for secondary bonding, then the bonding reliability is improved, but the curing time and capital expenditure are significantly increased

Engineering Contradiction:

Improvebonding reliabilityVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The curing of the encapsulant and the formation of the support frame structure occur simultaneously during the same lamination process cycle. The heat and pressure applied during lamination serve dual purposes: curing the encapsulant material while also setting the support frame structure in place, thereby eliminating separate curing time for adhesive bonding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laminate structure itself provides the bonding function through the encapsulant material that cures during lamination. The support frame is integrated into this self-curing system, where the encapsulant material serves both as the protective encapsulation layer and as the bonding medium that secures the support frame, eliminating the need for separate silicone-based adhesives and their associated curing processes.

Inventive Principle:

Principle #25Self-service

3Productivity

If a distributed support frame is adhered during lamination, then manufacturing costs and time are reduced, but the weight of the PV panel is reduced

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidpanel weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The support frame is constructed from cost-effective materials that are integrated directly into the laminate structure during manufacturing. By using materials that are inexpensive and can be processed during the standard lamination cycle, the overall panel weight is reduced compared to traditional heavy-duty aluminum frames, while still providing adequate structural support for the PV modules.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 reduces manufacturing time and costs by integrating support frame attachment with the lamination process, eliminating the need for secondary adhesive bonding, resulting in a lighter, less expensive PV panel with improved stability against external loads.

Implementation Method 1

an adhesive layer between a back surface of the PV module and an interfacial surface of one or more support members or mounts

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The support members or mounts may be adhered to the PV module during a lamination process

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS11502640B2Photovoltaic panel having an adhered support frame

Publication Date: 2022.11.15 MAXEON SOLAR PTE LTD

AI summary

A photovoltaic panel having a distributed support frame adhered to a photovoltaic module is described. For example, the distributed support frame may include one or more support member or support mounts adhered to the photovoltaic module by an adhesive layer. The photovoltaic module may include layers bound together by an encapsulant. Accordingly, the distributed support frame may be attached to the photovoltaic module during a same lamination process used to laminate the photovoltaic module.