Resin Frame Liner for Solar Module Thermal Expansion

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Solution Overview

Problem

Conventional concentrator photovoltaic modules face issues with positional displacement of power generating elements due to thermal expansion of the metal bottom plate and inadequate withstand load strength of the resin frame body, leading to decreased power generation efficiency and potential frame damage.

Innovation Solution

Incorporating a resin frame body with a liner portion extending along the upper surface of the metal bottom plate, formed with glass fibers that have random orientations to match thermal expansion coefficients, and a shielding member to prevent heat damage, along with a screw and seal layer for secure positioning and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a metal bottom plate is used to ensure heat dissipation performance, then heat dissipation is improved, but thermal expansion causes positional displacement of power generating elements

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidpositional accuracy of power generating elements

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

A resin layer is introduced as an intermediary between the metal bottom plate and the power generating elements. This resin layer has a coefficient of thermal expansion matched to the power generating elements, serving as a buffer that absorbs thermal expansion differences and prevents positional displacement while allowing the metal plate to continue functioning for heat dissipation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coefficient of thermal expansion of the intermediate layer is specifically adjusted to match that of the power generating elements. By changing the thermal parameter of the intermediate material, the system accommodates thermal expansion without causing positional displacement of the mounted elements.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If a resin frame body is used to suppress production cost, then manufacturing cost is reduced, but withstand load strength is insufficient

Engineering Contradiction:

Improveproduction costVSAvoidwithstand load strength of frame body

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The frame body is constructed as a composite structure combining resin material with reinforcing fibers (such as glass fibers). This composite approach maintains the cost advantages of resin while significantly enhancing the mechanical strength and load-bearing capacity to support the weight of power generating elements.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If the frame body structure is simplified to reduce complexity, then device complexity is reduced, but thermal protection and structural support are compromised

Engineering Contradiction:

Improveframe body structure complexityVSAvoidthermal damage from sunlight

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The frame body is designed to perform multiple functions simultaneously: it provides structural support, acts as a thermal barrier to protect against sunlight-induced heating, and maintains mechanical strength. This multi-functional design achieves protection without significantly increasing structural 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

This configuration inhibits positional displacement of power generating elements and enhances the load-bearing capacity of the resin frame body, ensuring stable power generation and preventing thermal damage from sunlight.

Implementation Method 1

a concentrator photovoltaic module includes: a concentrating portion formed by arranging a plurality of lens elements each configured to concentrate sunlight

Methodology Applied

Scientific EffectConcentration of sunlight through lenses: Lens

Implementation Method 2

formed with glass fibers that have random orientations to match thermal expansion coefficients

Methodology Applied

Scientific EffectThermal expansion matching: Thermal Expansion

Data Source

PatentUS10825943B2Concentrating solar power generation module, concentrating solar power generation panel, and concentrating solar power generation device

Publication Date: 2020.11.03 SUMITOMO ELECTRIC INDUSTRIES LTD

AI summary

A concentrator photovoltaic module including: a concentrating portion formed by arranging a plurality of lens elements each configured to concentrate sunlight; and a housing configured to accommodate a plurality of power generating elements disposed at positions respectively corresponding to the lens elements, wherein the housing includes: a frame body formed from resin; and a bottom plate formed from metal, the bottom plate being mounted to the frame body and having the power generating elements mounted thereto, and the frame body includes: a frame body portion forming an outer frame; and a liner portion extending along an upper surface of the bottom plate at an inner side of the frame body portion, the liner portion having both end portions thereof formed integrally with the frame body portion.