Concentrator Photovoltaic Module Housing for Optical Axis Stability

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Solution Overview

Problem

Conventional photovoltaic modules face challenges in accurately applying concentrated sunlight to power generating elements on the optical axis, especially in severe outdoor environments, leading to inefficiencies in power generation.

Innovation Solution

A photovoltaic module design featuring a housing with a concentrating portion, a glass substrate lens coated with silicone or acrylic resin, and a side wall made from PET or PBT, which includes an optical-axis confirmation portion to ensure accurate alignment and thermal expansion matching, reducing power generation inefficiencies due to temperature changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional photovoltaic modules are used in severe outdoor environments, then they can operate continuously, but the concentrated sunlight cannot be accurately applied to power generating elements on the optical axis due to thermal expansion and mechanical stress

Engineering Contradiction:
Improvecontinuous operation in severe environmentVSAvoidoptical axis alignment accuracy
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the material parameter of the housing from conventional materials to resin materials (PET or PBT) with specific thermal expansion coefficients that match the optical components. This parameter change ensures that the housing expands and contracts at the same rate as the lens and power generating elements during temperature variations, maintaining optical axis alignment accuracy while allowing continuous operation in severe environments.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material selection by using resin materials (PET or PBT) for the housing that combine appropriate mechanical strength with thermal expansion properties matching the optical components. This composite approach resolves the contradiction by selecting materials whose thermal characteristics harmonize with the optical elements, preventing misalignment while ensuring reliable continuous operation.

Inventive Principle:
Principle #40Composite materials

2Manufacturing precision

If additional optical axis confirmation members and high-accuracy assembly procedures are implemented, then optical axis alignment accuracy is improved, but device complexity and manufacturing costs increase

Engineering Contradiction:
Improveoptical axis alignment accuracyVSAvoidassembly complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements the self-service principle by designing the housing itself to provide the optical axis confirmation function through integrated confirmation portions. The housing structure includes built-in features that automatically indicate optical axis alignment without requiring separate confirmation devices or complex assembly procedures. This eliminates additional components while maintaining high alignment accuracy, reducing both device complexity and manufacturing costs.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent merges the optical axis confirmation function into the housing structure itself by integrating confirmation portions directly into the housing. This consolidation eliminates the need for separate optical axis confirmation members and simplifies the assembly process, achieving high alignment accuracy without increasing device complexity.

Inventive Principle:
Principle #5Merging (Combining)

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 design enhances power generation efficiency by maintaining optimal sunlight concentration and reducing mechanical stress, while eliminating the need for additional optical axis confirmation members and high-accuracy assembly, thus lowering costs and improving reliability.

Implementation Method 1

a concentrating portion provided with a lens configured to concentrate sunlight

Methodology Applied
Scientific EffectLight concentration: Lens

Implementation Method 2

the lens includes: a glass substrate; and a silicone resin or an acrylic resin provided on the glass substrate, and the side wall is formed by use of PET (polyethylene terephthalate) or PBT (polybutylene terephthalate)

Methodology Applied
Scientific EffectThermal expansion matching: Thermal Expansion

Data Source

PatentUS11894804B2Photovoltaic module, photovoltaic panel, and production method for photovoltaic module
Publication Date: 2024.02.06 SUMITOMO ELECTRIC INDUSTRIES LTD
  • US11894804B2 patent drawing
  • US11894804B2 patent drawing
  • US11894804B2 patent drawing

AI summary

This photovoltaic module includes: a power generating element configured to receive sunlight to generate power; and a housing which is closed, the housing having: a concentrating portion provided with a lens configured to concentrate sunlight; a bottom portion in which the power generating element is disposed; and a side wall serving as an outer frame for the bottom portion and supporting the concentrating portion. The side wall is a resin molded body including a resin and glass fibers dispersed in the resin, the resin is one of PET (Polyethylene terephthalate), PBT (Polybutylene Terephthalate), and PP (Polypropylene), and the glass fibers are orientated, in the resin, along a crossing direction that crosses a direction of an optical axis of the lens.