Frameless Bifacial Solar Module With Backrails for Lower Shading
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Solution Overview
Problem
Existing solar panel mounting systems are costly due to the use of aluminum frames and suffer from reduced sunlight exposure and debris accumulation, which affects energy generation.
Innovation Solution
A frameless solar panel design utilizing bifacial laminates with backrails made of galvanized steel, stainless steel, or steel with anti-corrosive coatings, which are attached to the backside glass layer using adhesive compounds, providing structural support without the need for external frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame support is used to fix the solar module, then the module is mechanically resilient against wind and snow loads, but the frame volume and aluminum costs increase installation expenses
Solution Approach 1:
The patent removes the traditional aluminum frame from the solar module design, extracting only the essential function of mechanical support. The frameless module uses the laminate structure itself and separate mounting systems to provide the necessary mechanical resilience, eliminating the bulky aluminum frame that increased material costs and volume.
Solution Approach 2:
The laminate structure serves multiple functions: it provides mechanical support, electrical insulation, and structural integrity. The mounting system is designed to work with various laminate configurations, making the solution universally applicable across different solar module designs while reducing dependency on aluminum frames.
2Strength
If a frame support overlaps the edge of the laminate, then the module is structurally supported, but the sunlight received by the solar cells is reduced
Solution Approach 1:
The frame is completely removed from the design, eliminating the overlap that blocked sunlight from reaching the solar cells at the edges. The laminate structure and mounting system provide structural support without interfering with the optical path and energy capture of the solar cells.
Solution Approach 2:
The mounting system transitions from a two-dimensional frame overlaying the module to a three-dimensional configuration where mounting points are positioned at the corners or edges of the laminate, allowing structural support without blocking the active solar cell area.
3Stability of the object's composition
If a frame support is used, then the module is mechanically stable, but snow, dirt, and debris accumulate in the frame catch, further shading the solar cells
Solution Approach 1:
The frame structure that created debris accumulation zones is removed entirely. The frameless design eliminates the horizontal surfaces and corners where snow, dirt, and debris would collect and block sunlight, allowing these materials to slide off the laminate surface more easily.
Solution Approach 2:
The smooth, frameless laminate surface converts the potential harm of debris accumulation into a benefit by allowing snow and rain to slide off more effectively, self-cleaning the surface and maintaining optimal sunlight exposure without requiring additional maintenance.
4Reliability
If aluminum frames are used for solar module fixation, then the module is securely mounted, but the installation costs increase due to aluminum material costs
Solution Approach 1:
The aluminum frame is extracted from the design, eliminating the dependency on expensive aluminum materials. The mounting system uses alternative materials and configurations that achieve the same security function at lower material costs.
Solution Approach 2:
The design changes the material parameters from aluminum to potentially cheaper materials like steel or composite materials, while adjusting the structural parameters of the mounting system to maintain or improve mounting security without increasing overall installation costs.
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 design enhances energy generation by minimizing shading from frames and debris accumulation, while reducing material costs and improving load-bearing performance.
Implementation Method 1
The two backrails are each attached to the backside glass layer by an adhesive compound in contact with the flat top surface
Implementation Method 2
Solar cells, also known as photovoltaic cells, are semiconductors that convert light or solar radiation directly to electricity
Data Source
AI summary
A bifacial solar module is described. The bifacial module has a laminate with a sun-facing glass layer and a backside glass layer, and two backrails attached to the backside glass layer for structural support. The bifacial module has an array of solar cells within a laminate, and the laminate has exterior edges that are not in contact with a frame structure or clamps. Two bifacial modules may be combined in a space-saving solar panel packaging arrangement. Also described is a solar panel assembly, which includes a mounting system configured to attach the bifacial module to a torque tube of a tracking system.