PV Module Bi-Directional Couplings for Crack-Resistant Assembly

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Solution Overview

Problem

Existing photovoltaic (PV) modules are prone to cracking under environmental loading due to sagging and deflection, particularly with glass-glass laminates being costly, difficult to install, and susceptible to handling damage, necessitating a lighter and more economical solution that reduces deflection and mechanical failure.

Innovation Solution

A PV module assembly with bi-directional couplings and a support frame that includes a hash profile, using a front glass sheet and a rear polymer sheet, which reduces the support span and likelihood of cracking, and features snap and tongue-and-groove mechanisms for easy installation without tools, allowing load sharing between modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass-glass laminates are used for PV modules, then strength and durability are improved, but weight, cost, and installation difficulty increase

Engineering Contradiction:

Improvemodule strengthVSAvoidmodule weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs a hybrid laminate structure combining glass front sheet with polymer rear sheet, creating a composite material system that leverages the strength of glass while reducing the weight and cost associated with full glass-glass construction. This composite approach resolves the contradiction by achieving adequate structural strength without the full weight penalty of dual glass layers.

Inventive Principle:

Principle #40Composite materials

2Strength

If glass-glass laminates are used for PV modules, then strength and durability are improved, but installation ease deteriorates

Engineering Contradiction:

Improvemodule strengthVSAvoidinstallation ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The polymer rear sheet serves as a sacrificial, easily replaceable component that simplifies installation and handling. Unlike permanent glass-glass laminates, the polymer layer can be managed more flexibly during installation, reducing the operational complexity and improving ease of installation while maintaining the structural benefits of glass front protection.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If support span is reduced to prevent cracking, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecracking resistanceVSAvoidsupport structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The support frame is segmented into multiple sections with distributed support points across the module back surface. This segmentation creates multiple short support spans without requiring a single complex continuous structure, thereby improving cracking resistance through reduced span lengths while maintaining relatively simple modular support architecture.

Inventive Principle:

Principle #1Segmentation

4Reliability

If bi-directional couplings are added for load sharing, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improveload distributionVSAvoidcoupling mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bi-directional couplings are integrated into the support frame structure to perform multiple functions: providing mechanical support, enabling load sharing between adjacent modules, and facilitating modular assembly. This multi-functionality achieves improved reliability through load distribution while avoiding the need for separate dedicated coupling components, thereby limiting the increase in overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 provides an economical, reliable, and easy-to-install PV module assembly that reduces the likelihood of cracking and mechanical failure by distributing loads effectively, while being lighter and less costly than traditional glass-glass laminates.

Implementation Method 1

Photovoltaic (PV) cells, commonly known as solar cells, are well known devices for converting solar radiation into electrical energy

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

Methodology Applied

Scientific EffectDeflection reduction through structural design:

Implementation Method 3

Methodology Applied

Scientific EffectLoad distribution through mechanical coupling:

Data Source

PatentUS11855582B2Photovoltaic module having bi-directional couplings

Publication Date: 2023.12.26 MAXEON SOLAR PTE LTD

AI summary

Photovoltaic module systems are provided. These systems can comprise multiple photovoltaic laminates connected with one or more mechanical coupling pairs that extend beyond perimeter edges of individual photovoltaic laminates. The mechanical coupling pairs can be connected to ends of support members positioned beneath the photovoltaic laminates. During assembly, an additional photovoltaic laminate may be added to connected photovoltaic laminates that are previously connected and lie along a shared plane of reference via pairs of mechanical couplings.