Frameless Solar Module Mounting Holes in Active Cell Areas
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Solution Overview
Problem
Conventional mounting methods for frameless solar modules are complex, prone to wear, and do not allow for aesthetically appealing self-supporting structures, while also increasing production costs and reducing efficiency due to the need for adhesive bonding and limited use of photovoltaically active area.
Innovation Solution
The integration of mounting holes within the photovoltaically active region of frameless solar modules, specifically designed as coating-free zones, allows for secure and versatile mounting on module holders without additional support elements, enabling self-supporting structures and efficient use of the solar cell area, with sealants preventing moisture and dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesive bonding is used to attach reinforcement braces to frameless solar modules, then mounting is enabled, but the process becomes complex and susceptible to wear
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical fastening system using mounting holes and fasteners. This substitution eliminates the complexity and wear issues associated with adhesive application and curing processes, providing a more robust and maintainable mounting solution.
Solution Approach 2:
The patent extracts the mounting function from the adhesive bonding process by creating dedicated mounting holes in the carrier substrate. This separation allows the solar cell production area to remain intact while providing discrete, pre-planned locations for mechanical attachment, simplifying the overall mounting process.
2Ease of operation
If mounting holes are created in the carrier substrate, then simplified mounting is achieved, but production costs increase
Solution Approach 1:
The mounting holes are created in the carrier substrate during the solar module manufacturing process, before the module is shipped to the installation site. This preliminary action integrates the mounting feature into the base production line, avoiding the need for separate post-manufacturing modifications and reducing overall production costs.
Solution Approach 2:
The mounting holes serve multiple functions: they provide attachment points for mechanical fastening, maintain structural integrity of the carrier substrate, and are positioned to avoid interference with the photovoltaically active regions. This multi-functionality justifies the manufacturing steps while providing comprehensive mounting capability.
3Weight of moving object
If frameless solar modules are used, then reduced weight and lower production costs are achieved, but mounting becomes complex and aesthetically unappealing
Solution Approach 1:
The patent segments the mounting function from the solar cell structure by creating discrete mounting holes at specific locations on the carrier substrate. This segmentation allows the frameless design to maintain its weight advantage while providing distinct, pre-planned attachment points that simplify the mounting process and enable clean, aesthetically pleasing installations.
4Reliability
If coating-free zones are created for mounting holes, then secure mounting is enabled, but photovoltaically active area is reduced
Solution Approach 1:
The patent applies local quality by creating coating-free zones only in the specific areas where mounting holes are located, while maintaining the photovoltaically active coating in all other areas. This localized approach ensures secure mounting in the necessary regions without unnecessarily reducing the overall active area, optimizing both reliability and energy generation.
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 solution simplifies and cost-reduces the mounting process, allows for aesthetically attractive self-supporting structures, and maintains the efficiency of solar cell operation by utilizing the solar cell area effectively without degrading the solar cell performance.
Implementation Method 1
a layer structure is situated, by which a plurality of serially connected solar cells for photovoltaic energy generation is formed
Data Source
AI summary
A frameless solar module having a carrier substrate and a top layer connected thereto, between which there is a layer structure which forms a plurality of solar cells connected in series for the photovoltaic generation of power is described. The carrier substrate and/or the top layer of the frameless solar module is/are provided with mounting holes for mounting the solar module on a module bracket or for connection to at least one further solar module. The mounting holes are produced in a coating-free zone within a photovoltaically active region. Mounting arrangements having such a solar module which contain fixing elements which pass through the mounting holes are also described. Furthermore, a method for producing such a solar module in which the mounting holes are produced in the carrier substrate and/or in the top layer is also described.