Frameless Solar Module Mounting Holes for Self-Supporting Assembly
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Solution Overview
Problem
Conventional frameless solar modules have complex and costly assembly processes, and they are not suitable for self-supporting constructions, lacking an aesthetically pleasing solution and efficient use of the solar cell area.
Innovation Solution
A frameless solar module design with mounting holes in the carrier substrate and cover layer, allowing for simplified and cost-effective assembly, and enabling self-supporting constructions by using these holes for mounting and connection without additional support elements, while maintaining efficient solar cell production area usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional frameless solar modules use reinforcing struts glued to the carrier substrate for assembly, then the solar module can be mounted on a module holder, but the assembly process becomes complex and susceptible to wear
Solution Approach 1:
The patent removes the reinforcing strut component entirely and extracts the mounting function directly into the carrier substrate by integrating mounting holes into the substrate itself. This eliminates the need for separate reinforcing elements and simplifies the assembly process to direct fastening through the substrate.
Solution Approach 2:
The patent merges the mounting function with the carrier substrate by integrating mounting holes directly into the substrate structure. This combines the structural support function and the mounting function into a single integrated component, eliminating the need for separate reinforcing struts.
2Reliability
If conventional frameless solar modules use bonding for assembly, then the solar module can be mounted, but the assembly becomes susceptible to wear due to bonding
Solution Approach 1:
The patent replaces the chemical bonding mechanism with a mechanical fastening system. Instead of relying on adhesive bonds that are susceptible to wear and degradation, the design uses mechanical fasteners inserted through mounting holes in the carrier substrate, providing a more durable and wear-resistant connection.
3Ease of manufacture
If conventional frameless solar modules are designed without additional support elements, then reduced module weight and lower production costs are achieved, but they do not allow an aesthetically pleasing solution for self-supporting constructions
Solution Approach 1:
The patent makes the carrier substrate multi-functional by integrating mounting holes directly into it. The substrate simultaneously serves as the structural base for the photovoltaic layers and as the mounting interface for both module holder attachment and inter-module connections in self-supporting constructions, eliminating the need for separate support elements.
4Ease of operation
If mounting holes are added to the carrier substrate and cover layer, then simplified and cost-effective assembly is enabled, but the solar cell area may be reduced
Solution Approach 1:
The patent applies local quality by creating coating-free zones specifically at the mounting hole locations where photovoltaic coating is not applied, while maintaining full coating coverage in all other areas. This localized approach allows mounting holes to be functional without sacrificing overall solar cell area, as the uncoated zones are minimal and strategically positioned.
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 enables uncomplicated, varied, and cost-effective assembly of solar modules, allowing for aesthetically pleasing self-supporting constructions with reliable mounting and reduced mechanical stress, while maintaining the efficiency of the solar cells by ensuring all cells operate at the same operating point.
Implementation Method 1
a layered structure, through which a plurality of serially connected solar cells for photovoltaic energy generation is formed
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
The invention relates to 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 up in series for the photovoltaic generation of power, wherein the carrier substrate and/or the top layer 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 each produced in a coating‑free zone within a photovoltaically active region. The invention also relates to mounting arrangements having such a solar module which contain fixing elements which pass through the mounting holes. Furthermore, it extends to 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. In this case, the layer structure is removed in coating‑free zones which contain the mounting holes or which are provided for producing the mounting holes.