Solar Cell Module Positioning Portions for Thermal Stability
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Solution Overview
Problem
Solar cell modules mounted on vehicles face positional instability due to thermal expansion and contraction of components, particularly when using lightweight resins like polycarbonate, which can damage interconnectors and displace solar cells.
Innovation Solution
A solar cell module design featuring a first and second cover with positioning portions to securely position conductors, eliminating the need for sealing material between the covers and the conductor, and using thermal caulking to integrate the positioning portion with the conductor, ensuring stability during thermal expansion and contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight resin (polycarbonate) is used for the front plate to reduce weight, then weight reduction is achieved, but thermal expansion and contraction causes positional displacement of members and damage to interconnectors
Solution Approach 1:
Positioning portions are provided on the front plate and rear plate before the laminating process to pre-establish stable reference positions for conductors and solar cells. This preliminary positioning structure ensures that even when thermal expansion and contraction occur during operation, the conductors and solar cells maintain stable positions relative to the plates, preventing displacement and interconnector damage.
2Reliability
If sealing material is used to surround the conductor, then electrical connection is maintained, but positional stability of the conductor is compromised due to material interposition
Solution Approach 1:
The space within the sealing material is segmented into two functional zones: a conductor positioning space that directly contacts the conductor for precise positioning and electrical connection, and a sealing material region that surrounds but does not contact the conductor. This segmentation allows the conductor to be stably positioned by the positioning portions while still being protected by the sealing material, eliminating the trade-off between electrical connection and positional accuracy.
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 reliably positions conductors and prevents solar cell displacement, maintaining module integrity and aesthetic appeal while reducing manufacturing complexity and material usage.
Implementation Method 1
front and back plates thermally expand and contract, and each member may positionally be displaced
Implementation Method 2
the positioning portion has a tip thermally caulked to position the conductor
Data Source
AI summary
A solar cell module includes: a first cover in the form of a plate having at least a portion transparently; a second cover disposed to face the first cover; at least one solar cell disposed between the first cover and the second cover; a sealing material which fills a space between the first cover and the second cover and joins them together to thus seal the solar cell; and terminals electrically connected to the solar cell, surrounded by the sealing material between the first cover and the second cover, and serving as a conductor. At least one of the first cover and the second cover has a boss as a positioning portion which positions the terminals. The terminal contacts the first cover having the boss.