Solar Cell Module With Insulating Adhesive Mounting
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Solution Overview
Problem
Existing solar cell modules face challenges in achieving reliable electrical insulation between solar cell units and the base plate, particularly under high voltage conditions, and in preventing short circuits due to environmental factors like condensation.
Innovation Solution
A solar cell module design where each solar cell unit is secured to a metallic base plate using a thermally conductive and electrically insulating adhesive, with a secondary optical element non-positively connected via a polymer adhesive layer, and electrical contact established through resistance spot welding, ensuring insulation and thermal coupling without additional fastening means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solar cell units are mounted directly on a metallic base plate, then mechanical stability is improved, but electrical insulation deteriorates leading to short circuit risks
Solution Approach 1:
A frame structure made of electrically insulating material is introduced as an intermediary between the solar cell units and the metallic base plate. This frame provides both mechanical support and electrical insulation, preventing direct contact between conductive elements and the metal plate while maintaining structural stability.
Solution Approach 2:
The mounting system uses composite construction combining different materials with complementary properties: electrically insulating materials for the frame and mounting elements, thermally conductive materials for heat dissipation components, and metallic materials for structural support. This multi-material approach simultaneously achieves mechanical stability and electrical insulation.
2Reliability
If additional insulation measures are added to prevent short circuits, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The frame structure is designed to perform multiple functions simultaneously: providing mechanical support for solar cell units, ensuring electrical insulation between conductive elements and the base plate, and facilitating thermal management. This multi-functional design eliminates the need for separate insulation components, reducing overall device complexity.
Solution Approach 2:
The mounting and insulation functions are merged into a single integrated frame structure. Rather than using separate mounting brackets and insulation layers, the frame combines both functions in one component, simplifying the overall device architecture while maintaining reliable electrical insulation.
3Temperature
If thermal coupling is enhanced for heat dissipation, then temperature management is improved, but electrical insulation may deteriorate
Solution Approach 1:
The thermal management system is segmented into distinct functional zones: thermally conductive paths for heat dissipation are provided through designated mounting points and heat sinks, while electrically insulating materials are used in areas where electrical isolation is critical. This spatial segmentation allows simultaneous optimization of both thermal coupling and electrical insulation.
Solution Approach 2:
Different material properties are applied locally to different areas of the device: highly thermally conductive materials are used at contact points with the base plate for efficient heat transfer, while electrically insulating materials are used in areas where electrical isolation is needed. This local differentiation of material properties enables both heat dissipation and electrical insulation to be optimized in their respective zones.
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 design provides reliable electrical insulation and thermal management, preventing short circuits and allowing for efficient heat distribution, while simplifying the manufacturing process by integrating insulation and thermal conductivity in a single adhesive layer.
Implementation Method 1
The underside of each carrier is force-fitted to a first portion of the surface of the base plate by means of a thermally conductive and electrically insulating adhesive
Implementation Method 2
The underside of each carrier is force-fitted to a first portion of the surface of the base plate by means of a thermally conductive and electrically insulating adhesive
Implementation Method 3
the secondary optical element, which consists in particular of a glass, is preferably connected in a non-positive manner to the carrier and the solar cell on the upper side only by means of an organic agent, in particular a polymer adhesive layer
Implementation Method 4
Electrical contact with the solar cell unit is established via contact surfaces arranged on the carrier surface. The contact surfaces are electrically connected to a metallic connecting element, for example by resistance spot welding
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a solar cell module consisting of a plurality of solar cell units arranged on a surface of a metal base plate, each solar cell unit comprising a holder with an upper side and a lower side, a semiconductor body arranged on the upper side of the holder and embodied as a solar cell, and a secondary optical element arranged on the semiconductor body, the holder of each solar cell unit respectively covering a first region of the surface of the base plate, and the lower side of each holder being non-positively connected to the first region of the surface of the base plate by means of a heat-conductive and electrically insulating adhesive. A second region of the surface of the base plate completely surrounding the holder in a projection extending perpendicularly to the surface of the base plate is completely covered with the adhesive around each holder.