Lightweight Photovoltaic Module With Structured Rear Layer
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Solution Overview
Problem
Conventional photovoltaic modules with thick glass front faces are heavy, making them unsuitable for applications requiring lightness, while alternatives using thinner glass or polymer materials compromise mechanical resistance, failing to meet IEC 61215 and IEC 61730 standards.
Innovation Solution
A photovoltaic module design featuring a thin glass or polymer front face and a three-dimensional rear face with reliefs, providing mechanical reinforcement while reducing weight, achieved through a combination of materials like tempered glass, polymers, and composite materials, and a modified lamination process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick glass (3 mm) is used for the front face, then mechanical strength is improved, but weight increases to approximately 12 kg/m²
Solution Approach 1:
The invention transitions from a two-dimensional flat rear face to a three-dimensional structured rear face with reliefs and recesses. This dimensional change allows the rear layer to provide mechanical reinforcement through its three-dimensional geometry rather than relying solely on material thickness, enabling weight reduction while maintaining strength
Solution Approach 2:
The invention uses composite material structures, particularly in the rear layer which combines polymeric materials with reinforcing elements. The multilayer construction with different materials (PET, PVF, PVDF, aluminum foil) creates a composite structure that provides both lightness and mechanical strength
2Weight of stationary object
If thinner glass or polymer materials are used for the front face, then weight is reduced, but mechanical resistance decreases and IEC 61215 and IEC 61730 standards are not met
Solution Approach 1:
By creating a three-dimensional rear face structure with reliefs and recesses, the invention compensates for the reduced material thickness. The three-dimensional geometry provides structural support and mechanical resistance that would otherwise require thicker materials, enabling compliance with IEC standards while achieving weight reduction to less than 7 kg/m²
Solution Approach 2:
The rear layer features localized reinforcement through reliefs and recesses positioned at specific locations. This local quality approach provides mechanical strength where needed most (at the rear face) without adding weight across the entire module, allowing thin front face materials to be used while maintaining overall structural integrity
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 results in a photovoltaic module with a significantly lower surface weight (less than 7 kg/m²) while maintaining mechanical properties equivalent to traditional modules, allowing for use in demanding applications without compromising structural integrity.
Implementation Method 1
a photovoltaic module is an assembly of photovoltaic cells arranged side by side between a first transparent layer forming a front face of the photovoltaic module and a second layer forming a rear face of the photovoltaic module
Implementation Method 2
adhesion is created at all the interfaces between the layers, namely between the front face 2 and the front layer of encapsulation material 3a, the layer of encapsulation material 3a and the front faces 4a of the photovoltaic cells 4
Data Source
Figure 1~3
Figure 4A~4B
Figure 5A~5D
AI summary
The main subject matter of the invention is a lightweight photovoltaic module (1) comprising: a first transparent layer (2) forming the front face; photovoltaic cells (4); an assembly (3) encapsulating the photovoltaic cells (4); and a second layer (5) forming the rear face and comprising an inner surface (8i) and an outer surface (8e). The encapsulating assembly (3) and the photovoltaic cells (4) are located between the first (2) and second (5) layers. The module is characterised in that: the first layer (2) is made from glass and/or polymer material and has a thickness (e2) that is less than or equal to 1.1 mm; the inner surface (8i) is substantially planar; and the second layer (5) comprises raised portions (9) projecting from the outer surface (8e), said outer surface (8e) and raised portions (9) together defining the visible rear outer surface of the photovoltaic module (1).