Photovoltaic Concentrator Module Sealing with UV and Silicone
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Solution Overview
Problem
Current photovoltaic concentrator modules are costly to produce and have limited long-term stability, making it difficult to integrate additional components effectively.
Innovation Solution
A method involving a frame with two different sealing compounds, one for UV curing and another for long-term sealing, is used to connect a lens plate and a baseplate, allowing for cost-effective and durable production of concentrator modules with improved integration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sealing compound is used to connect the lens plate and baseplate, then the manufacturing process is simple, but the long-term stability and resistance to environmental stresses are insufficient
Solution Approach 1:
The sealing compound is divided into two distinct functional layers: a first sealing compound (UV-curing adhesive) that provides immediate bonding and structural stability, and a second sealing compound (silicone-based sealant) that provides long-term environmental protection and flexibility. This segmentation allows each layer to specialize in its optimal function, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The patent employs a composite sealing system combining two different material types with complementary properties. The UV-curing adhesive provides rigid structural bonding, while the silicone sealant provides flexible environmental sealing. This composite approach achieves superior long-term stability without excessive complexity.
2Adaptability or versatility
If additional components are integrated into the concentrator module, then the functionality and adaptability are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The frame structure with the two-layer sealing compound system serves multiple functions: structural support, optical alignment, environmental sealing, and a flexible platform for integrating additional components. This universal design allows various components (heatsinks, mounting brackets, additional optics) to be added without fundamentally redesigning the sealing system, thus improving adaptability without proportional increases in complexity.
3Use of energy by moving object
If traditional silicon solar cells are used, then the manufacturing is well-established, but the conversion efficiency of sunlight to electrical power is limited
Solution Approach 1:
The patent changes the fundamental material parameter of the photovoltaic cell from traditional silicon to compound semiconductors (III-V族化合物半导体 such as GaAs, InP). This parameter change enables significantly higher energy conversion efficiency by utilizing different bandgap properties that are better suited for concentrated sunlight applications, while the modular concentrator design maintains ease of manufacture through standardized assembly processes.
4Power
If concentrated sunlight is used to increase power output, then the energy density is improved, but the requirements for precision and stability increase
Solution Approach 1:
The patent employs a lens plate with a convex outer surface that concentrates sunlight onto the photovoltaic cell. The curved optical surface provides inherent optical precision and tolerance to alignment variations, allowing high power output without requiring extremely tight manufacturing tolerances for the entire module assembly. The curvature focuses light effectively even with moderate positioning variations.
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 enables the industrial production of photovoltaic concentrator modules that are both cost-effective and have a long service life, with enhanced flexibility in integrating components and improved resistance to environmental stresses.
Implementation Method 1
vornehmlich durch Bestrahlung mit UV-Licht (40) fixiert wird
Implementation Method 2
konzentrieren die Sonnenstrahlung mittels Linsen oder Spiegeln auf die kleinen Solarzellen
Data Source
AI summary
Apparatus for the industrial production of photovoltaic concentrator modules, consisting of a module frame, a lens disc, a sensor carrier disc and an electrical line routing arrangement, comprising the following features: a) a mount for the stress-free mounting of a module frame by means of clamping elements on both longitudinal sides and stop elements on both transverse sides, wherein the setting of the clamping elements takes place by means of the displacement and rotation of a switching rod, b) a device for a punctiform application of acrylic and a linear application of silicone onto the bearing surfaces of the module frame, c) a respective device for placing the sensor carrier disc or the lens disc, wherein these discs are transported in a stress-free fashion by means of special suction apparatuses and are emplaced with a centrally starting, predetermined contact pressure, d) a device for measuring the respective disc position and for positioning a sensor carrier disc or a lens disc, e) a device for the fine adjustment of the lens disc with respect to the CPV sensors of the sensor carrier disc by means of a camera, wherein the camera is adjusted in such a way that the position of its optical axis impinges on the geometrical midpoint of a CPV sensor, f) a device for curing the silicone application between the module frame and the respective disc by means of a plurality of UV light emitters, and g) devices for transporting the workpieces to be processed.