Solar Module Support Structure with Angled Reinforcement Ribs
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Solution Overview
Problem
Current solar modules face issues with warping and curling of the support portion, leading to uneven pressure distribution and potential damage when mass is applied, and they are limited in size due to these defects, which also affects the stability and flatness on varying roof structures.
Innovation Solution
A solar module design featuring a support portion with reinforcement ribs that extend at an angle, providing a uniform and stable surface for the active portion, and a polymeric construction that remains planar and free of warp, with an intermediate portion acting as a structural interface and gate locations for injection molding to form a frame around the active portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the size of the solar module is increased, then the power generation capacity is improved, but the support portion experiences increased warp and curl
Solution Approach 1:
The support portion is constructed as a composite structure with a core layer and skin layers bonded together. The core layer provides structural support while the skin layers constrain warping and curling. This composite construction allows the support portion to maintain dimensional stability even as the overall solar module size increases, thereby enabling larger modules without proportionally increasing deformation.
Solution Approach 2:
The support portion is divided into multiple layers (core layer and skin layers) that can be manufactured separately and then bonded together. This segmentation allows each layer to be optimized for its specific function and enables better control over the overall structural behavior, including warping resistance, while scaling to larger module sizes.
2Area of stationary object
If the support portion is made larger to support bigger solar modules, then the structural coverage is improved, but the flatness and stability deteriorate due to increased warp
Solution Approach 1:
The multi-layer composite construction of the support portion provides inherent dimensional stability. The bonded skin layers act as constraints that prevent the core layer from warping excessively, maintaining flatness even as the support portion area increases to accommodate larger solar modules.
Solution Approach 2:
The support portion incorporates localized reinforcement features such as ribs or stiffening elements in specific areas where warping is most likely to occur. This local quality enhancement provides targeted stability without requiring a uniform increase in thickness or material throughout the entire support portion.
3Ease of manufacture
If the support portion is made thinner to reduce weight and cost, then the manufacturing cost is reduced, but the strength and ability to resist warp increase
Solution Approach 1:
The composite construction allows the support portion to achieve high strength-to-weight ratio. By bonding multiple thin layers together, the structure gains increased stiffness and warp resistance compared to a single thick layer of equivalent weight. This enables thinner, lighter, and less expensive support portions that still maintain the required mechanical properties.
Solution Approach 2:
The skin layers of the support portion function as thin constraint films that effectively control the deformation of the thicker core layer. These thin films provide significant structural benefit with minimal material usage, reducing overall weight and manufacturing cost while maintaining strength and warp resistance.
Data Source
AI summary
A solar module (2) comprising; (a) an active portion (4) and (b) a support portion (6), wherein the support portion (8) includes a plurality of reinforcement ribs (20) in a series of interconnected or partially interconnected patterns. The solar module (2) may include an intermediate portion (6C) acting as a structural interface between the active portion (4) and the support portion (6). The intermediate portion (6C) may include one or more gate locations (10, 12). The plurality of reinforcement ribs (20) may extend at an angle along the support portion (6) so that an effective modulus of the support portion (6) along a width direction is substantially equal to an effective modulus of the support portion (6) along a length direction.