Lightweight Composite Photovoltaic Module Design
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Solution Overview
Problem
Conventional photovoltaic modules are heavy due to the use of thick glass, which limits their suitability for applications requiring lightness and flexibility, such as building roofs, street furniture, and nomadic applications, while also being vulnerable to mechanical loading and differential expansions.
Innovation Solution
Replacing the standard thick glass with a multilayer polymer/fiber composite material for the front face and modifying the rear face to include a polymer/fiber composite material, along with the addition of a damping intermediate film to improve adhesion and resistance to thermal expansions, and using prepreg-based composite materials for both layers to enhance mechanical and thermomechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick glass is used for the front face of photovoltaic modules, then mechanical strength and protection are improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining polymer matrices with fiber reinforcements (glass, carbon, or aramid fibers) to create lightweight yet mechanically strong front and rear faces. This composite structure provides the necessary mechanical strength while significantly reducing weight compared to conventional thick glass, achieving weight per unit area of less than 5 kg/m² while maintaining structural integrity.
2Object-affected harmful factors
If thick glass is used for the front face, then protection is improved, but thickness and weight increase
Solution Approach 1:
The composite material structure with fiber reinforcement provides superior protection against mechanical loading and differential expansions while maintaining reduced thickness. The fiber-polymer composite achieves the required protective function with thinner sections compared to conventional glass, contributing to the overall reduced module thickness.
3Weight of stationary object
If polymer/fiber composite materials are used for front and rear faces, then weight is reduced, but adhesion and resistance to thermal expansions may be compromised
Solution Approach 1:
The patent introduces a damping intermediate film as an intermediary layer between the composite material faces and the encapsulating assembly. This intermediate film serves as a mediator that enhances adhesion and provides resistance to thermal expansions, resolving the reliability concerns associated with using lightweight polymer/fiber composite materials while maintaining the weight reduction benefits.
Solution Approach 2:
The patent modifies the rear face to include a polymer/fiber composite material with specific properties optimized for thermal management and adhesion. By changing the material parameters and structure of the rear face composite, the patent enhances overall adhesion and resistance to thermal expansions while maintaining the lightweight characteristic.
4Weight of stationary object
If standard thick glass is replaced with composite materials, then weight and thickness are reduced, but mechanical resistance may be compromised
Solution Approach 1:
The patent employs fiber-reinforced polymer composite materials for both front and rear faces, where the fiber reinforcement (glass, carbon, or aramid) provides the necessary mechanical resistance while the polymer matrix binds the fibers and provides structural continuity. This composite approach achieves weight per unit area of less than 5 kg/m² while maintaining adequate mechanical resistance for photovoltaic module applications.
Solution Approach 2:
The patent applies different fiber types and configurations in different locations (front face versus rear face) to optimize local mechanical properties. The front face composite may use fibers optimized for impact resistance, while the rear face composite may use fibers optimized for tensile strength and thermal expansion resistance, achieving overall mechanical resistance with reduced weight.
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
The solution results in a lighter photovoltaic module with improved mechanical resistance and reduced thickness, achieving a surface weight of less than 4 kg/m² while maintaining excellent mechanical and thermomechanical properties, and providing protection against ultraviolet radiation and aging.
Implementation Method 1
photovoltaic cells arranged side by side between a first transparent layer forming a front face of the photovoltaic module and a second layer forming a rear face of the photovoltaic module
Data Source
Figure 1~2
Figure 3~4
AI summary
The main object of the invention is a lightweight photovoltaic module (1) comprising: a first transparent layer (2) forming the front face, photovoltaic cells (4), an assembly encapsulating (3) the photovoltaic cells (4), and a second layer (5) forming the rear face of the photovoltaic module (1), the encapsulating assembly (3) and the photovoltaic cells (4) being located between the first (2) and second (5) layers, characterized in that the first layer (2) comprises a first composite layer (2c), a first intermediate damping film (2b), and a first protective film (2a), and in that the second layer (5) comprises a second composite layer (5a).