Slim Solar Module Frame Structure for Lower Transport Volume

Solution Overview

Problem

Conventional solar modules are optimized for mechanical stability and longevity but not for reducing overall system costs, particularly transportation costs, which are influenced by the module's volume.

Innovation Solution

A solar module design featuring a solar laminate with a transparent front and rear cover sheet, enclosed by a frame with a optimized thickness ratio and reinforced with at least one strut, reducing the module's volume while maintaining mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the frame thickness is reduced to decrease module volume, then transportation costs are reduced, but mechanical stability deteriorates

Engineering Contradiction:

Improvemodule volumeVSAvoidmechanical stability

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

The frame is segmented into multiple thin-walled profile sections that work together to provide structural support. The profile includes a rear wall, front wall, and connecting webs that divide the frame into functional zones, allowing each segment to contribute to overall stability while maintaining thin walls for reduced volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame utilizes a composite profile structure combining multiple materials or material layers with different properties. The profile includes a rear wall, front wall, and connecting webs that create a composite structural system, optimizing both mechanical strength and volume efficiency through material composition rather than relying on thick single-material walls.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If the frame thickness is reduced to decrease module volume, then transportation costs are reduced, but strength deteriorates

Engineering Contradiction:

Improvemodule volumeVSAvoidframe strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The frame is segmented into multiple thin-walled profile sections that work together to provide structural support. The profile includes a rear wall, front wall, and connecting webs that divide the frame into functional zones, allowing each segment to contribute to overall stability while maintaining thin walls for reduced volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame utilizes a composite profile structure combining multiple materials or material layers with different properties. The profile includes a rear wall, front wall, and connecting webs that create a composite structural system, optimizing both mechanical strength and volume efficiency through material composition rather than relying on thick single-material walls.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If conventional frame design is used, then mechanical stability is maintained, but volume is larger increasing transportation costs

Engineering Contradiction:

Improvemechanical stabilityVSAvoidmodule volume

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The frame employs thin-walled profile structures that function as flexible yet strong structural elements. The thin walls are designed with optimized geometry including rear walls, front walls, and connecting webs that provide sufficient mechanical stability while minimizing material usage and overall volume compared to conventional thick-framed designs.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The frame design changes key geometric parameters including wall thickness, profile shape, and structural configuration. By optimizing these parameters, the frame achieves adequate mechanical stability with significantly reduced volume compared to conventional designs, directly addressing the transportation cost issue.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12283914B2Cost effective frame design for thinner wafers

Publication Date: 2025.04.22 REC SOLAR PTE LTD

AI summary

A slim solar module is proposed. It comprises a solar laminate comprising plural solar cells interposed between front and rear cover sheets, a frame enclosing the solar laminate and at least one reinforcement strut arranged at a rear surface of the solar laminate. A ratio between a frame surface and a frame thickness shall be between 45000 and 70000. For example, the frame may have a thickness of less than 35 mm. Specifically, the frame may have a length of 1665 mm, a width of 991 mm and a thickness of 30 mm. Due to the reduced thickness, the solar module has a reduced volume being beneficial during transport to a destination location. However, the thickness has been optimized to, with the reinforcement struts, still providing for sufficient mechanical stability for the solar module.