Photovoltaic Module Support Layer Stiffening
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Solution Overview
Problem
Photovoltaic (PV) module assemblies are heavy and expensive due to the weight of aluminum frames and glass layers, and replacing glass with plastic reduces mechanical properties, necessitating a solution that enhances mechanical performance without increasing weight.
Innovation Solution
Incorporating a support layer with stiffening elements between thermoplastic layers in the PV module assembly, which can include a honeycomb or triangular array pattern, to improve stiffness and flexural strength while maintaining a lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass and aluminum frame are used in PV module assembly, then mechanical strength and structural stability are improved, but weight and production cost increase
Solution Approach 1:
The patent changes the material parameters from traditional glass and aluminum to polymer materials with optimized mechanical properties. Specifically, it uses polycarbonate or other high-strength polymers that provide sufficient mechanical strength while significantly reducing weight compared to glass and aluminum frame constructions.
Solution Approach 2:
The patent employs composite material structures where multiple polymer layers are combined to achieve both mechanical strength and weight reduction. The back layer comprises multiple polymer layers that work together to provide structural support without the weight penalty of traditional glass and aluminum frame combinations.
2Weight of moving object
If glass is replaced with polymer material, then weight is reduced, but mechanical properties deteriorate
Solution Approach 1:
The patent selects polymer materials with specific mechanical parameters that match or exceed the performance requirements previously met by glass. By carefully choosing polymers with appropriate tensile strength, flexural strength, and stiffness parameters, the invention achieves weight reduction without sacrificing mechanical properties.
Solution Approach 2:
The patent combines multiple polymer layers in the back layer structure to collectively provide the mechanical strength that a single thick glass layer would have provided. This layered polymer construction achieves both weight reduction and maintained mechanical properties through synergistic material combination.
3Weight of moving object
If polymer material is used for collector, then weight is reduced, but optical efficiency decreases
Solution Approach 1:
The patent optimizes the optical parameters of polymer materials by selecting materials with high light transmission characteristics. The chosen polymers are engineered or treated to minimize light absorption and scattering, ensuring that optical efficiency parameters remain high despite the material substitution from glass to polymer.
4Stability of the object's composition
If frame and glass layer are used, then structural stability is improved, but production cost and assembly time increase
Solution Approach 1:
The patent integrates the frame function directly into the polymer back layer structure, eliminating the need for separate frame components. This merging of structural functions into a single polymer assembly reduces the number of parts, simplifies production processes, and decreases assembly time while maintaining structural stability.
Solution Approach 2:
The polymer back layer serves multiple functions simultaneously: it provides structural stability, mechanical strength, and structural support without requiring separate dedicated components. This multi-functionality reduces assembly complexity and improves production rate by eliminating the need to assemble multiple separate structural elements.
Data Source
AI summary
A photovoltaic module assembly, comprising: a first layer; a back layer, wherein the back layer comprises a second layer, a third layer, and a support layer located between the second layer and the third layer; and a photovoltaic layer comprising photovoltaic cells, wherein the photovoltaic layer is located between the first layer and the back layer; wherein the support layer comprises a stiffening element.