Photovoltaic Module With Localized Contact Elements For Thermal Stress
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Solution Overview
Problem
Existing photovoltaic module production methods face challenges such as increased material costs, production delays, and risk of cell breakage due to different thermal expansion coefficients between glass and silicon, as well as inefficiencies in heat dissipation and mechanical stress on cells.
Innovation Solution
A photovoltaic module design utilizing localized contact elements (LKE) for selective, minimal fixation and spacing between cover layers, allowing for sliding contact and adhesive connections to manage thermal expansion and reduce mechanical loads, with a method involving application and curing of these elements to ensure efficient heat dissipation and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If encapsulation material is used to enclose cells between cover layers, then cells are protected and connected to cover layers, but material costs increase and production time is delayed due to lamination step
Solution Approach 1:
The invention extracts and eliminates the encapsulation material from the module structure, transitioning from a fully enclosed design to an edge-sealed design with gas filling. This removes the lamination step entirely, reducing production time and material costs while maintaining cell protection through the edge seal and gas pressure system
Solution Approach 2:
The invention introduces gas filling (pneumatic element) into the module structure to replace the mechanical encapsulation material. The gas provides pressure to hold cells in position and protects them from breakage without requiring lamination, thus eliminating the time-consuming lamination step while maintaining reliability
2Stability of the object's composition
If cells are fixed to cover layers at multiple points, then mechanical stability is improved, but heat dissipation is impeded due to thermal expansion coefficient differences
Solution Approach 1:
The invention segments the fixation system from a continuous or multi-point contact into discrete localized contact elements (LKE). Each LKE provides isolated mechanical support and electrical connection points, allowing the cell surface to remain largely free for heat dissipation while maintaining structural stability through distributed discrete contact points
Solution Approach 2:
The invention applies local quality by creating localized contact zones (LKE) rather than extensive contact areas. The LKE have specific material properties (conductivity, adhesion) concentrated at precise locations, providing mechanical stability and electrical connection only where needed, while the majority of the cell surface remains thermally active for heat dissipation
3Quantity of substance
If thin wafers are used to reduce material costs, then manufacturing costs decrease, but the risk of cell breakage increases under mechanical loads
Solution Approach 1:
The invention implements beforehand cushioning by introducing a gas-filled structure that provides mechanical cushioning and stress distribution before external loads are applied to thin wafers. The gas pressure creates a supportive environment that prevents direct impact and distributes mechanical stresses, protecting thin cells from breakage during handling and operation
Solution Approach 2:
The invention changes the mechanical parameter environment for thin wafers by replacing solid encapsulation with a compressible gas medium. This parameter change (from rigid to compliant support) allows thin cells to flex and accommodate thermal and mechanical stresses without fracturing, enabling the use of thinner, more cost-effective wafers while maintaining reliability
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 minimizes mechanical loading on photovoltaic cells, reduces manufacturing effort, and enhances heat dissipation by using localized contact elements that allow for flexible connections and reduced material usage, addressing the limitations of prior art while maintaining module stability and efficiency.
Implementation Method 1
differences in thermal expansion between the cell and the cover layer do not lead to critical stresses
Implementation Method 2
enhances heat dissipation by using localized contact elements
Data Source
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AI summary
The invention relates to a photovoltaic module comprising a first and a second cover layer, an arrangement of photovoltaic cells connected via cell connectors located therebetween and a peripheral seal of the cover layers surrounding the photovoltaic module. The module according to the invention enables a minimization of the mechanical stress, such as by differing thermal expansion coefficients, of the photovoltaic cells. The invention further relates to a method for producing the photovoltaic modules according to the invention.