Glass-Free Photovoltaic Panel Packaging for Lighter Module Assembly
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Solution Overview
Problem
Traditional solar photovoltaic modules are heavy and thick due to the use of glass panels, which increases production costs and complicates recycling, while also reducing light capture efficiency.
Innovation Solution
A photovoltaic panel packaging structure and method that eliminates the use of glass panels by employing a frame with grooves and encapsulating layers, allowing for reduced weight and thickness, simplified assembly, and easy recycling by applying heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass panels are used in traditional solar modules, then structural strength and protection are improved, but weight and thickness increase significantly
Solution Approach 1:
The patent removes the glass panel from the traditional solar module structure, extracting the heavy protective element while maintaining structural integrity through alternative materials (frame and encapsulating layers). This directly resolves the contradiction by eliminating the source of weight and thickness problems while preserving protective functions.
Solution Approach 2:
The patent uses thin film encapsulating layers (EVA or similar materials) to replace the thick glass panel. These flexible thin films provide necessary protection and sealing while adding minimal weight and thickness, directly addressing the weight reduction goal while maintaining structural adequacy.
2Strength
If glass panels are used in traditional solar modules, then protection is improved, but light capture efficiency decreases due to multiple reflections
Solution Approach 1:
By removing the glass panel that causes multiple internal reflections, the patent eliminates the harmful optical effect. The alternative frame and thin film structure does not create the same reflection problems, thereby improving light capture efficiency while maintaining protection through different mechanisms.
Solution Approach 2:
The patent changes the optical parameters of the protective structure by replacing glass with materials having different refractive indices and optical properties. This reduces light reflection and improves transmission to the solar cells, directly addressing the light capture efficiency issue.
3Strength
If glass panels and complex encapsulation structures are used, then protection and sealing are improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent simplifies the manufacturing process by removing the glass panel installation step and reducing the number of encapsulation layers needed. The frame structure with integrated grooves for receiving solar cells and encapsulating materials reduces assembly steps and manufacturing complexity while maintaining adequate protection and sealing.
Solution Approach 2:
The patent combines multiple functions into the frame structure - it provides structural support, contains grooves for cell positioning and encapsulation, and serves as a protective enclosure. This merging of functions reduces the number of separate components and simplifies the overall manufacturing process.
4Strength
If glass panels and complex encapsulation structures are used, then protection is improved, but recycling and dismantling become difficult
Solution Approach 1:
The patent segments the solar module into easily separable components: frame, solar cells, and encapsulating layers. The frame can be detached and reused, and the encapsulating layers can be removed to access the solar cells for recycling. This segmentation directly improves recyclability compared to the integrated glass panel structure.
Solution Approach 2:
The patent facilitates the recovery and reuse of valuable components. The metal frame can be recovered and reused in new modules, and the solar cells can be accessed and recycled more easily without the need to break through thick glass panels, directly improving the economics and feasibility of recycling programs.
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 reduces the weight and thickness of photovoltaic panels, simplifies the assembly process, and facilitates quick and easy recycling, while also enhancing light capture efficiency by eliminating multiple reflections through glass.
Implementation Method 1
applying heat and pressure, facilitating a rapid and simplified dismantling process
Implementation Method 2
applying heat and pressure, facilitating a rapid and simplified dismantling process
Data Source
AI summary
The present invention provides a photovoltaic panel packaging structure and method for the same. The packaging structure comprises a frame and a solar photovoltaic panel. The solar photovoltaic panel includes a first frame surface and a second frame surface with a receiving space and grooves formed therein. The a solar photovoltaic panel is installed in the receiving space and stacked on top of a first stop portion. The solar photovoltaic panel includes a first encapsulating layer, a second encapsulating layer. The first encapsulating layer includes a plurality of engaging strips extending along the edges of the solar photovoltaic panel, the engaging strips are respectively embedded in the corresponding grooves to hold the solar photovoltaic panel in place in the frame. Meanwhile, a third encapsulating layer extends to connect to the second frame surface. As a result, weight and thickness can be reduced while reducing multiple packaging passes and simplifying the assembly process.