Embossed Solar Module Back Element for Load Support and Cooling
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Solution Overview
Problem
Existing solar module designs face challenges with mechanical stress, inefficient cooling, and high production and transport costs due to the use of thick glass substrates and frame or backrail systems, which lead to inhomogeneous stress distribution and reduced packing density, hindering efficient energy conversion and increasing the risk of cell breakage.
Innovation Solution
A back element for solar modules formed from a sectionally cut and embossed material web, with sections arranged in parallel planes to absorb loads and facilitate heat dissipation, eliminating the need for a circumferential frame and allowing for improved mechanical support and cooling, while reducing material usage and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thick glass substrates and high frames are used to transfer surface loads, then mechanical stability is improved, but device complexity and cost increase
Solution Approach 1:
The back element is divided into multiple load-bearing struts arranged in a grid pattern, where each strut independently supports surface loads. This segmentation distributes mechanical stress across multiple discrete elements rather than requiring a single thick frame, reducing overall complexity while maintaining stability
Solution Approach 2:
The back element transitions from a two-dimensional flat structure to a three-dimensional configuration with struts extending perpendicular to the module surface. This dimensional change creates spatial separation between load application points and the module backsheet, improving mechanical stability without increasing planar complexity
2Strength
If high frames are used to support surface loads, then mechanical strength is improved, but packing density during shipping decreases
Solution Approach 1:
The frame is segmented into discrete struts positioned only at critical load-bearing locations rather than forming a continuous high structure around the entire module perimeter. This reduces the overall volume occupied by support structures while maintaining mechanical strength where needed
Solution Approach 2:
Instead of providing full circumferential support with a continuous frame, the invention uses partial support through strategically placed struts that provide sufficient mechanical strength only in areas where loads are applied, eliminating excessive material and volume
3Stability of the object's composition
If closed frame profiles are used for mechanical support, then structural stability is improved, but heat dissipation from the rear is hindered
Solution Approach 1:
The back element employs an open strut configuration with gaps between individual support elements, creating a porous structure that allows air flow through the space between struts. This enables convection currents to pass through rather than being blocked by solid frame profiles, improving heat dissipation while maintaining structural stability
Solution Approach 2:
The continuous frame profile is segmented into discrete struts with spaces between them, transforming the structure from a solid barrier to a permeable support system that allows thermal convection while maintaining mechanical function
4Ease of operation
If frame assembly is performed manually with labor-intensive processes, then assembly flexibility is maintained, but productivity decreases
Solution Approach 1:
The back element is pre-assembled as a single integrated component with all struts and connectors manufactured as one piece or pre-configured units. This preliminary assembly eliminates the need for complex on-site frame assembly operations, enabling direct attachment to the module and significantly improving productivity
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 effectively absorbs surface loads, reduces mechanical stress on solar cells, enhances heat dissipation, and lowers production and transport costs by allowing for a thinner module design with improved packing density and reduced risk of cell breakage, while maintaining efficient energy conversion.
Implementation Method 1
the material web sections produced from the material web by forming and cutting form openings in the rear element at least in sections in those areas in which they do not lie in the same plane
Implementation Method 2
heat dissipation from the rear is unfavorable. The efficiency of solar modules decreases at higher temperatures, so good cooling increases efficiency. However, the closed frame profiles actually hinder convection currents
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a rear face element for a solar module, said element being made of a material sheet that is shaped, in particular embossed and/or stamped. Some sections of the material sheet are arranged on a first plane, and some sections are arranged on at least one second plane parallel to the first plane. The material sheet forms spacer elements in a transition region between the first and the second plane in order to space the first plane from the second plane, and at least one first material sheet section extends from a first lateral edge to an opposing second lateral edge of the material sheet continuously, in particular in a linear manner. The invention also relates to a solar module and to a method for producing a solar module.