Non-Conductive PV Module Frame With Expansion Groove Clearance
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Solution Overview
Problem
Photovoltaic panels with polymer frames face issues with thermal warping and expansion, which can cause mechanical stresses and render the solar cell panels inoperable.
Innovation Solution
The use of non-conductive interchangeable frames that accommodate the solar cell panels with grooves sized to allow expansion, limiting binding and mechanical stresses, and enabling individual module replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polymer frames are used to reduce weight, then the panel weight is reduced by 50%, but the coefficient of thermal expansion increases causing thermal warping and mechanical stresses
Solution Approach 1:
The frame is divided into multiple segments with grooves that allow the solar cell panel to expand independently in different directions. This segmentation enables the frame to accommodate thermal expansion without transmitting uniform stress across the entire panel, resolving the contradiction between using lightweight polymer material and preventing thermal warping.
Solution Approach 2:
The groove dimensions are specifically designed with clearance parameters that change to accommodate thermal expansion. The grooves are sized to provide sufficient space for the solar cell panel to expand when heated, while still maintaining mechanical support. This parameter adjustment allows the polymer frame to function effectively despite its high thermal expansion coefficient.
2Strength
If the frame tightly holds the solar cell panel, then mechanical support is improved, but thermal expansion causes binding and bowing of the panel
Solution Approach 1:
The frame design transitions from a static rigid structure to a dynamic system that adapts to thermal conditions. The grooves allow the solar cell panel to move dynamically within the frame boundaries, expanding when hot and contracting when cool, while the frame continuously provides mechanical support. This dynamic accommodation prevents binding and maintains panel flatness throughout temperature cycles.
Solution Approach 2:
The grooves act as intermediary spaces between the solar cell panel and the frame walls. These intermediate zones absorb the dimensional changes caused by thermal expansion, preventing direct contact and binding between the expanding panel and the rigid frame structure. This intermediary space resolves the contradiction between providing mechanical support and allowing thermal movement.
3Reliability
If the whole panel is replaced when one module fails, then reliability is maintained, but the loss of time and material increases
Solution Approach 1:
The photovoltaic panel is segmented into multiple independently replaceable modules, each with its own frame and solar cell panel assembly. This segmentation allows individual module replacement rather than whole panel replacement, maintaining system reliability while minimizing time and material loss. The standardized module design with integrated frames enables quick swap-out of failed modules without affecting other sections.
Solution Approach 2:
The modular design enables selective discarding of only the failed module while recovering and retaining all other functional modules. This approach significantly reduces material waste compared to replacing the entire panel, and reduces replacement time since only one module needs to be handled and installed rather than the complete panel assembly.
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 effectively mitigates thermal expansion issues, allows for easy replacement of individual modules, and maintains panel functionality, while also providing flexibility in panel configuration and connection types.
Implementation Method 1
Polymer frames have a higher coefficient of thermal expansion than glass... The grooves are sized so that the solar cell panel can expand into the frame
Data Source
AI summary
A photovoltaic panel and an interchangeable module are described. The photovoltaic panel includes a plurality of interchangeable modules that are mechanically and electrically interconnected. Each module includes a solar cell panel with electrically conductive ribbons providing electrical connections, the solar cell panel having a face extending between peripheral edges, a cell length, and a cell width; a frame receiving the solar cell panel that includes a front portion defining a central aperture through which the face of the solar cell panel is exposed; and a back portion attached to the front portion, the front portion and the back portion defining a groove extending around the central aperture and open to the central aperture, the groove having a groove length at least 10 millimeters longer than the cell length and a groove width at least 10 millimeters longer than the cell width, the solar cell panel received in the groove.