Spacing element
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Solution Overview
Problem
Existing solar modules face issues with indeterminate distance between the frame and flat elements, leading to potential sealing and adhesive failures due to thermal expansion and mechanical loads, resulting in liquid leakage and mechanical stress.
Innovation Solution
A spacer with a base section and a spacer section that projects angularly to provide a defined minimum distance between the flat element and the profile elements, featuring centering sections for precise alignment and resilient properties to compensate for manufacturing tolerances and ensure a consistent sealing and adhesive joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealant and adhesive are used to hold flat elements in the frame, then the flat elements can be mounted, but the distance between the frame and flat element becomes indeterminate, leading to sealing joint failure
Solution Approach 1:
A spacer element is introduced as an intermediary component between the flat element and the profile element. The spacer has a defined geometry with a base section and a spacer section that projects angularly, providing a predetermined distance and ensuring reliable sealing joint thickness without relying solely on adhesive application control.
Solution Approach 2:
The spacer section is designed with specific geometric parameters (projection length, angle) that directly determine the distance between the flat element and profile element. By controlling these geometric parameters during manufacturing, the sealing joint thickness is precisely controlled, resolving the indeterminate distance problem.
2Reliability
If the sealing joint thickness is too thin or uneven, then material usage is reduced, but the sealing joint tears open under thermal expansion and mechanical loads
Solution Approach 1:
The spacer acts as a mechanical intermediary that ensures minimum sealing joint thickness is maintained regardless of adhesive application variations. This prevents sealing joint failure under thermal and mechanical stresses while using adhesive only as a bonding agent rather than the primary spacing mechanism.
3Reliability
If more sealant and adhesive are applied to ensure sufficient sealing, then sealing reliability improves, but the cost and complexity increase
Solution Approach 1:
The spacer provides mechanical spacing and support, reducing reliance on large amounts of adhesive for positioning and support. The adhesive's primary function becomes bonding rather than structural support, potentially simplifying the installation process while maintaining sealing reliability.
4Ease of manufacture
If the flat element is mounted directly without spacers, then the installation process is simpler, but the distance and sealing joint thickness cannot be controlled
Solution Approach 1:
The spacer is designed as a simple component that integrates into the existing mounting process. The base section interfaces with the groove in the profile element, while the spacer section provides the distance control, adding minimal complexity to the installation while significantly improving distance definition.
Data Source
AI summary
A spacer (1) is used to provide a defined minimum distance (A) between a flat element (2), such as a photovoltaic laminate or solar glass or window glass, and profile elements (3) with a groove (4) in which the flat element ( 2) is stored. The spacer (1) has a base section (5) and a spacer section (6) which is molded onto the base section (5) and protrudes at an angle from the base section (5), with at least the spacer section (6) between the flat element (2) and the profile element (3), in particular the groove (4), comes to rest.