Manufacturing a concentrating sub-module comprising a heat-dissipating material
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Solution Overview
Problem
The manufacture of concentrating photovoltaic sub-modules is complex and inefficient due to the need for multiple steps, including forming and polishing reflective surfaces, bonding photovoltaic cells, and inadequate heat dissipation, which affects the efficiency and lifetime of the modules.
Innovation Solution
A single-step method for manufacturing concentrating photovoltaic sub-modules using a multi-layer assembly that includes a structural element with a reflective face, a layer of high thermal conductivity material, an encapsulant or adhesive, a photovoltaic receiver, and transparent encapsulating and protective layers, where the reflective face is shaped by contact with a convex counter-mold to achieve a concave geometric shape for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple manufacturing steps (forming, polishing, bonding) are used to create concentrating photovoltaic sub-modules, then the structural precision and optical performance are improved, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent combines multiple manufacturing steps (forming, polishing, and bonding) into a single extrusion process. The multi-layer assembly is extruded through a die that simultaneously forms the reflective surface geometry, bonds the layers together, and creates the final sub-module structure in one continuous operation, eliminating the need for separate forming, polishing, and bonding steps.
Solution Approach 2:
The patent prepares the multi-layer assembly with pre-configured layers (reflective layer, structural layers, photovoltaic cells, encapsulants) in the correct sequence and orientation before extrusion. The die geometry is pre-designed with the desired reflective surface profile, so the extrusion process directly produces the final shaped component without requiring subsequent forming or polishing operations.
2Manufacturing precision
If traditional multi-step manufacturing is used, then manufacturing precision can be achieved, but production efficiency and productivity decrease
Solution Approach 1:
The extrusion process operates continuously, feeding the multi-layer assembly through the die and producing concentrating photovoltaic sub-modules in an uninterrupted stream. This eliminates the stop-start nature of traditional multi-step processes where each operation (forming, polishing, bonding) would require separate setup, execution, and transition time, thereby maintaining high productivity while ensuring consistent geometric accuracy.
3Reliability
If heat dissipation structures are added to improve thermal management, then the lifetime and efficiency are improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The extrusion die serves multiple functions simultaneously: it forms the reflective concentrator surface, bonds the multi-layer assembly, and integrates heat dissipation features into the structural layers. The structural layers themselves are designed to provide thermal management, eliminating the need for separate heat dissipation components and reducing overall device complexity while improving reliability.
4Weight of moving object
If composite materials are used to reduce weight, then the mechanical strength and weight ratio are improved, but the thermal conductivity decreases affecting heat dissipation
Solution Approach 1:
The patent applies different material properties to different layers and regions of the sub-module. Lightweight composite materials are used in structural layers where weight reduction is critical, while heat dissipation pathways are created through specific layer configurations, thermal interfaces, and conductive elements positioned at locations where heat transfer is most needed, optimizing both weight and thermal performance locally rather than uniformly across the entire structure.
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 method enables efficient heat dissipation and improved mechanical strength, maintaining module efficiency and extending its lifetime by effectively managing temperature gradients and reducing manufacturing complexity.
Implementation Method 1
a layer of a material of good thermal conductivity, higher than that of the material from which the structural element is composed, said layer being placed on the second face of the structural element
Data Source
AI summary
A method for manufacturing a concentrating photovoltaic solar sub-module equipped with a reflective face having a concave predefined geometric shape, wherein it includes laminating, in a single step, a multi-layer assembly comprising in succession: a structural element equipped with a reflective first face and a second face, opposite the first; a layer of a material of good thermal conductivity, higher than that of the material from which the structural element is composed, the layer being placed on the second face of the structural element; a layer of encapsulant or of adhesive; a photovoltaic receiver, the layer of encapsulant or of adhesive being placed between the layer of a material of good thermal conductivity and the receiver; a layer made of transparent encapsulating material, covering at least the entire surface of the photovoltaic receiver; and a transparent protective layer covering the layer made of transparent encapsulating material; and during the lamination, the reflective face of the structural element is shaped by being brought into contact with a convex surface of a counter-mold, in order to obtain the reflective face of concave predefined geometric shape.