Lightweight Photovoltaic Module Front Layer With Thin Glass Composite

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional photovoltaic modules are heavy due to the use of thick glass for the front face, making them unsuitable for applications requiring lightweight solutions while maintaining mechanical strength and resistance to impacts.

Innovation Solution

A photovoltaic module design featuring a transparent polymer front layer combined with a thin glass layer, both thinner than 2 mm, and a polymer-based rear layer with enhanced mechanical properties, replacing the standard thick glass to achieve reduced weight and improved impact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thick glass is used for the front face of photovoltaic modules, then mechanical strength and resistance to impacts are improved, but weight increases significantly

Engineering Contradiction:

Improvemechanical strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining thin glass layers (≤2mm) with polymer materials to create a front face structure that achieves both lightweight properties and sufficient mechanical strength. The composite structure includes a thin glass layer for optical transparency and a polymer layer for mechanical protection, replacing the conventional thick glass structure.

Inventive Principle:

Principle #40Composite materials

2Reliability

If thick glass is used for the front face, then resistance to impacts is improved, but weight per unit area increases above 5 kg/m2

Engineering Contradiction:

Improveresistance to impactsVSAvoidweight per unit area

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent uses composite materials combining thin glass (≤2mm) with polymer materials to achieve impact resistance while maintaining lightweight properties. The polymer layer absorbs impact energy and protects the thin glass structure, enabling the module to meet impact resistance requirements with a weight per unit area below 5 kg/m2.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements beforehand cushioning by incorporating a polymer layer behind the thin glass front face. This polymer layer acts as a cushion that absorbs impact energy before it reaches the photovoltaic cells, providing prior protection against impacts while keeping the overall structure lightweight.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Weight of moving object

If thin glass layer is used, then weight is reduced, but mechanical strength and resistance to impacts deteriorate

Engineering Contradiction:

ImproveweightVSAvoidmechanical strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent compensates for the reduced mechanical strength of thin glass by combining it with polymer materials in a composite structure. The polymer layer provides the necessary mechanical strength and protection, allowing the use of thin glass (≤2mm) while maintaining overall structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses an intermediary polymer layer that mediates between the thin glass front face and the photovoltaic cells. This intermediary layer protects the thin glass from mechanical stresses and impacts, enabling the use of lightweight thin glass without compromising the overall mechanical strength of the module.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Weight of moving object

If standard thick glass is replaced, then weight is reduced below 6 kg/m2, but durability and resistance to thermomechanical expansions may worsen

Engineering Contradiction:

Improveweight per unit areaVSAvoiddurability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses composite materials combining thin glass with polymer materials that have compatible thermal expansion coefficients. This composite structure reduces weight to below 6 kg/m2 while maintaining durability through the synergistic properties of the combined materials, which together provide resistance to thermomechanical expansions.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20240379886A1Lightweight photovoltaic module including a glass and polymer front layer

Publication Date: 2024.11.14 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A photovoltaic module obtained from a stack includes: a first transparent layer forming the front face; a plurality of photovoltaic cells; an assembly encapsulating the plurality of cells; and a second layer forming the rear face. The first layer includes: a front layer made of at least one polymer material; at least one front assembly comprising an interface front layer and a glass front layer, with a thickness smaller than or equal to 2 mm, the at least one front assembly being located between the polymer front layer and the encapsulating assembly, and the interface front layer of the at least one front assembly being located between the polymer front layer and the glass front layer.