Segmented Solar Module Reinforcement for Crack Resistance
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Solution Overview
Problem
Solar modules are prone to cracking due to bending, which can degrade their performance, despite the use of glass sheets for protection, as large glass sheets can still bend and cause mechanical stress on the laminate structure.
Innovation Solution
Individual solar cells or small groups of solar cells are reinforced with a strong, rigid material like hard plastic or glass, allowing for flexible connections and a frameless design that absorbs mechanical stress without cracking, using flexible conductors and cover layers for electrical connectivity and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large glass sheets are used to protect solar cells from bending, then the protection against mechanical stress is improved, but the glass sheets themselves can still bend and cause cracks in the laminate structure
Solution Approach 1:
The patent divides the solar module into multiple independently reinforced sections, each with its own local reinforcement structure. This segmentation allows each section to handle mechanical stress independently, preventing crack propagation across the entire module while maintaining flexibility in the gaps between sections.
Solution Approach 2:
The patent applies reinforcement locally at specific positions where solar cells are most vulnerable to bending stresses, rather than using uniform large glass sheets across the entire module. This localized reinforcement approach provides targeted protection while allowing other areas to remain flexible.
2Stability of the object's composition
If glass sheets and external frames are used to stiffen the laminate structure, then resistance to bending is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent removes the external frame structure from the solar module design, relying instead on integrated local reinforcements embedded within the laminate structure itself. This extraction of the frame simplifies the overall device complexity while maintaining structural stability through the distributed reinforcement approach.
Solution Approach 2:
The patent merges the reinforcement function directly into the laminate structure by integrating local reinforcement elements with the solar cells and encapsulant layers. This integration eliminates the need for separate external framing components, reducing device complexity while maintaining bending resistance.
3Strength
If rigid glass sheets are attached to the outer frame, then mechanical protection is improved, but the ability to flex and adapt to complex surfaces is reduced
Solution Approach 1:
The patent segments the rigid reinforcement elements into small local sections separated by flexible gaps. This segmentation allows each rigid section to provide mechanical protection while the flexible gaps between sections enable the overall module to bend and adapt to complex installation surfaces.
Solution Approach 2:
The patent uses flexible encapsulant materials and thin film structures to connect the rigid local reinforcement sections. These flexible elements allow the module to conform to curved or irregular surfaces while the rigid sections maintain mechanical protection, achieving both strength and adaptability.
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 enhances the durability and flexibility of solar modules, reducing the need for large glass sheets and external frames, enabling installation on complex surfaces and simplifying the manufacturing and installation process while maintaining performance.
Implementation Method 1
The laminate structure includes an active layer formed by a plurality of interconnected solar cells which are responsible for converting light into electricity
Implementation Method 2
The individual reinforcement is formed of a strong, rigid material, such as hard plastic or glass... enabling installation on complex surfaces... absorbing mechanical stress without cracking
Implementation Method 3
The solar module includes flexible conductors that extend through the gap between the solar cells and electrically connect the solar cells to each other
Implementation Method 4
Each of the solar cells has an individual reinforcement laminated to one face of each of the solar cells... The transparent cover layer is attached to an outer face of each of the individual reinforcements
Data Source
AI summary
A solar module includes a laminate structure having at least two solar cells. Each of the solar cells has an individual reinforcement laminated to one face of each of the solar cells. The solar cells are spaced apart from each other and the individual reinforcements are spaced apart from each other such that a gap is defined between each of the solar cells. The solar module includes flexible conductors that extend through the gap between the solar cells and electrically connect the solar cells to each other.