Composite Reinforcement Frame for Lightweight Photovoltaic Modules
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Solution Overview
Problem
Conventional photovoltaic modules are too heavy due to the use of thick glass and aluminum frames, making them unsuitable for applications requiring lightweight solutions while maintaining mechanical resistance and compliance with standards like IEC 61215 and IEC 61730.
Innovation Solution
A photovoltaic module design featuring a composite reinforcement frame with a higher Young's modulus than traditional materials, replacing the aluminum frame and incorporating a transparent composite structure that allows for reduced weight and increased rigidity, using materials like polymer resin and fibers, and a sandwich structure with a low-density core for further weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick glass and aluminum frames are used in conventional photovoltaic modules, then mechanical resistance and structural integrity are improved, but weight increases significantly making them unsuitable for lightweight applications
Solution Approach 1:
The patent applies composite materials by combining polymer resin matrices with reinforcing fibers (glass, carbon, or aramid) to create a frame that achieves high mechanical strength while maintaining low weight. The composite frame provides structural integrity comparable to traditional aluminum frames but with significantly reduced density, enabling lightweight applications such as portable photovoltaic systems and drone integration.
Solution Approach 2:
The patent implements local quality by creating a sandwich structure with a low-density core and composite reinforcement layers only where structurally necessary. This allows the frame to have varying thickness and reinforcement density across different regions, optimizing mechanical performance while minimizing overall weight. The core provides bulk structural support while the skin layers provide surface strength and stiffness.
2Weight of moving object
If traditional aluminum frames are replaced with composite materials, then weight is reduced, but manufacturing complexity increases due to integration of multiple layers and materials
Solution Approach 1:
The patent merges multiple functions into a single integrated composite frame structure. The frame simultaneously provides structural support, edge protection, and mounting attachment points, eliminating the need for separate components. The sandwich structure combines the core and skin layers into one monolithic unit that can be manufactured in a single process, reducing assembly complexity despite the multi-material composition.
Solution Approach 2:
The patent segments the frame into distinct functional zones: a low-density core for weight reduction and bulk support, and reinforced skin layers for surface strength and stiffness. This segmentation allows each layer to be optimized independently for its specific function while being manufactured as an integrated structure, simplifying the design process despite the multi-material nature.
3Loss of substance
If the frame structure is optimized for weight reduction, then material usage is decreased, but mechanical integrity and compliance with IEC standards may be compromised
Solution Approach 1:
The patent applies parameter changes by systematically varying the fiber volume fraction, fiber orientation, resin matrix composition, and layer thickness to achieve the optimal balance between weight reduction and mechanical performance. These parameters are tuned to meet specific IEC 61215 and IEC 61730 certification requirements for load resistance, thermal cycling, and durability while minimizing material usage.
Solution Approach 2:
The patent uses composite materials with high strength-to-density ratios to reduce material usage while maintaining or improving mechanical integrity. The combination of polymer resin and reinforcing fibers creates a material system that provides superior specific strength compared to traditional aluminum, allowing thinner sections and reduced material volume while meeting all certification standards for structural reliability.
Data Source
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AI summary
The main object of the invention is a photovoltaic module (1) obtained from a stack comprising at least: a first layer (2), a plurality of photovoltaic cells (4), an assembly encapsulating (3) the photovoltaic cells (4), characterized in that it further comprises: a composite structure (10) forming a frame for the photovoltaic module (1), comprising an intermediate layer (13) and a composite reinforcement frame (12) of higher rigidity superimposed on one or more predetermined first zones (P) of the intermediate layer (13), the frame (12) having a Young's modulus greater than 10 GPa at 25°C. The composite structure is a sandwich-type structure, comprising a main layer forming the core (14) and two first (13) and second (16) covering layers forming skin layers, one of which is formed by the intermediate layer.The core (14) of the composite structure (10) is at least partly formed by a low density structure of less than 500 kg/m3.