Solar Module Expanded Metal Mesh Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar modules face efficiency drops due to thermal expansion mismatch between photovoltaic elements and thermally conductive layers, leading to mechanical stresses and reduced heat transfer efficiency.
Innovation Solution
A solar module design utilizing a thermally conductive expanded metal mesh with a plurality of holes, which absorbs thermal expansion changes in shape rather than dimension, maintaining mechanical and thermal contact with the photovoltaic element, and integrating a cooling line within the expanded metal for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal plate is used as a thermally conductive layer and glued to the photovoltaic element, then thermal contact is improved, but mechanical stresses cause the connection to tear or detach due to different coefficients of thermal expansion
Solution Approach 1:
The patent applies an expanded metal mesh with a porous structure as the thermally conductive layer. This mesh structure absorbs thermal expansion stresses through its open geometry while maintaining thermal contact with the photovoltaic element, resolving the contradiction between heat transfer efficiency and connection stability under temperature fluctuations.
Solution Approach 2:
The patent creates a composite structure by bonding the expanded metal mesh to the photovoltaic element using an adhesive layer. This composite construction combines the thermal conductivity of metal with the flexibility of the mesh structure and adhesive, allowing thermal contact while accommodating differential thermal expansion between materials.
2Temperature
If pressure elements made of spring steel are used to press the heat-conducting layer onto the photovoltaic element, then thermal contact is maintained, but the solar module becomes structurally more complex and heavier
Solution Approach 1:
The patent removes the complex spring steel pressure elements from the design. Instead, the expanded metal mesh itself maintains thermal contact through its inherent structural properties and bonding to the photovoltaic element, eliminating the need for separate mechanical pressure application systems.
3Temperature
If individual metal strips are arranged on cooling lines and elastically deformed to contact the photovoltaic element, then thermal contact is maintained, but the thermally conductive layer becomes very complicated and difficult to produce
Solution Approach 1:
The patent merges the function of multiple individual metal strips into a single continuous expanded metal mesh structure. This mesh can be produced as one piece and bonded to the photovoltaic element as a unit, eliminating the need for individual assembly of multiple strips while maintaining thermal contact across the entire surface.
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 maintains thermal contact and reduces mechanical stresses, improving heat dissipation and photovoltaic efficiency while simplifying manufacturing and reducing material weight.
Implementation Method 1
the at least one thermally conductive layer has at least one metal expanded mesh with a plurality of holes... which absorbs thermal expansion changes in shape rather than dimension
Implementation Method 2
at least one cooling line that is in thermal contact with the at least one heat-conducting layer
Data Source
Figure 1~3
AI summary
Solar module (6) with at least one photovoltaic element (8), at least one heat-conducting layer which is in thermal contact with the at least one photovoltaic element, and at least one cooling line (16) which is in thermal contact with the at least one heat-conducting layer, characterized in that the at least one heat-conducting layer has at least one expanded metal grid (2) with a plurality of holes (4).