Solar Power Module Insulation Structure for Parasitic Capacitance Reduction

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Solution Overview

Problem

Existing solar power modules experience increased parasitic capacitance due to the proximity of aluminum alloy frames and solar panels, which affects photoelectric conversion efficiency, particularly in thin-film solar cells where additional capacitance is generated by the aluminum film and frame, and conventional solutions like foam tape fail to provide lasting separation.

Innovation Solution

A solar power module design incorporating a solar panel, a metallic frame, soft insulation glue material, and a hard insulation spacer made of polyethylene terephthalate (PET) or acryl, with the spacer maintaining a critical height of at least 0.5 mm to separate the solar panel from the metallic frame, reducing parasitic capacitance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If double sided foam tape is used to increase the distance between the solar panel and the aluminum alloy frame, then parasitic capacitance is reduced initially, but after a long period of time the foam tape becomes thinner due to compression and parasitic capacitance increases again

Engineering Contradiction:

Improvelong-term parasitic capacitance controlVSAvoidfoam tape thickness maintenance

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent combines soft insulation glue material (compressible, providing initial cushioning) with a hard insulation spacer (rigid, maintaining long-term distance) to create a composite insulation structure. This composite approach allows the soft material to absorb initial compression while the hard spacer maintains the critical distance over time, preventing the foam tape thinning problem.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulation structure is divided into two functional segments: a soft insulation glue material layer and a hard insulation spacer. Each segment performs a different function - the soft material provides initial compression and sealing, while the hard spacer maintains the critical distance. This segmentation allows each component to optimize its specific function rather than requiring a single material to do everything.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the distance between the aluminum film and the aluminum alloy frame is enlarged to reduce parasitic capacitance, then photoelectric conversion efficiency is improved, but the structural strength and stability may be compromised

Engineering Contradiction:

Improvephotoelectric conversion efficiencyVSAvoidmodule structural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The hard insulation spacer acts as an intermediary element between the solar panel (with aluminum film) and the aluminum alloy frame. It maintains the optimal distance for reducing parasitic capacitance while also serving as a structural support element. The spacer is positioned in the groove of the frame, providing both electrical isolation and mechanical strength to the overall module structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a hard insulation spacer with sufficient height is used to maintain distance, then parasitic capacitance is reduced effectively, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveparasitic capacitance reductionVSAvoidinsulation structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hard insulation spacer is strategically positioned only at the lower portion where the solar panel meets the frame, rather than providing insulation along the entire perimeter. The spacer has a specific L-shaped cross-section that fits into the groove, providing insulation exactly where the parasitic capacitance problem occurs most severely, while keeping the overall structure simple and manufacturable.

Inventive Principle:

Principle #3Local quality

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

Effectively reduces parasitic capacitance by maintaining a consistent safe distance between the solar panel and metallic frame, even when the soft insulation glue material degrades, thereby enhancing the photoelectric conversion efficiency and durability of the module.

Implementation Method 1

it is easy to generate parasitic capacitance between the solar panel and the aluminum alloy frame

Methodology Applied

Scientific EffectParasitic capacitance: Capacitance

Implementation Method 2

The hard insulation spacer is disposed between the solar panel and the lower portion of the metallic frame

Methodology Applied

Scientific EffectDielectric separation: Dielectric

Implementation Method 3

The soft insulation glue material is fixedly disposed in the metallic frame

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10312393B2Solar power module

Publication Date: 2019.06.04 HULK ENERGY TECH

AI summary

A solar power module includes a solar panel, a metallic frame, a soft insulation glue material, and a hard insulation spacer. The solar panel is embedded in the metallic frame. The metallic frame includes an upper portion, an intermediate portion, and a lower portion. The soft insulation glue material is adapted to wrap at least one portion of an edge of the solar panel. The soft insulation glue material is fixedly disposed in the metallic frame. The soft insulation glue material to wrap the solar panel is divided into an upper part, an intermediate part, and a lower part. The hard insulation spacer is disposed between the solar panel and the lower portion of the metallic frame.