Stiffened Photovoltaic Module Structure for Thermal Flatness
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Solution Overview
Problem
Existing photovoltaic modules face issues with thermal stress-induced deformations such as bending and waviness, which affect their flatness and long-term performance, and there is a need for lightweight and cost-effective solutions, particularly for terrestrial and extraterrestrial applications.
Innovation Solution
Incorporation of stiffeners, specifically longitudinal stiffeners, between the strings of photovoltaic cells within the module, which enhance rigidity and reduce deflection during thermal cycling, along with the use of lightweight polymer materials for protective layers and optional reinforcing layers to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a photovoltaic module is designed without additional stiffening structures, then the manufacturing cost and device complexity are reduced, but the module becomes prone to thermal stress-induced deformations such as bending and waviness during thermal cycling
Solution Approach 1:
The module is divided into segments by inserting stiffeners between strings of photovoltaic cells. These stiffeners create discrete sections that prevent thermal stress from causing continuous bending and waviness across the entire module, thereby improving resistance to thermal deformation while maintaining relatively simple construction.
Solution Approach 2:
Stiffeners are strategically positioned between strings of photovoltaic cells rather than uniformly across the entire module. This localized approach provides structural support precisely where thermal stress-induced deformations occur most frequently, improving reliability without unnecessarily increasing overall device complexity.
2Reliability
If traditional heavy backing structures are used to prevent deformation, then structural stability is improved, but the module weight increases
Solution Approach 1:
The patent employs thin stiffener elements and flexible encapsulating materials that provide necessary structural support without the weight of traditional heavy backing structures. These thin-film approaches maintain structural stability while significantly reducing overall module weight for terrestrial and extraterrestrial applications.
Solution Approach 2:
The module utilizes composite material structures combining photovoltaic cells, encapsulants, and stiffeners in an integrated design. This composite approach achieves structural stability through material properties and geometric configuration rather than relying on heavy single-material backing, thereby reducing weight while maintaining reliability.
3Manufacturing precision
If stiffeners are added between strings of photovoltaic cells, then deflection during thermal cycling is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
Stiffeners are pre-positioned between strings of photovoltaic cells before the final encapsulation and lamination steps. This preliminary placement ensures correct positioning and simplifies the manufacturing process, as the stiffeners are already in place to guide subsequent assembly operations and maintain flatness during thermal cycling.
Solution Approach 2:
The stiffeners are integrated into the module assembly process and combined with the encapsulation and lamination steps. Rather than being separate post-manufacturing additions, the stiffeners are merged into the primary manufacturing flow, reducing the number of discrete operations and simplifying overall manufacturing while maintaining manufacturing precision.
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 significantly reduces deflection and waviness during thermal cycles, enabling the module to withstand thousands of cycles between -120°C to +120°C, while maintaining a lightweight and cost-effective design suitable for various applications.
Implementation Method 1
A photovoltaic module contains photovoltaic cells designed to convert radiant or light energy into electrical energy
Data Source
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AI summary
Photovoltaic module (M) comprising a front face (1) and a rear face (3) between which is arranged an encapsulant (2) of photovoltaic cells (20), the module (M) comprising a plurality of strings each of one or more photovoltaic cells (20), the photovoltaic cell(s) (20) of a string being placed in series along a longitudinal axis of the string, the module (M) further comprising a plurality (10) of stiffeners (11, 12) arranged between the front face (1) and the rear face (3), the plurality (10) of stiffeners comprising at least one longitudinal stiffener (11) placed between the strings of photovoltaic cells (20), so as to extend longitudinally between two strings of photovoltaic cells (20) and one or more transverse stiffeners (12) arranged between one or more strings and an edge of the photovoltaic module.At least one longitudinal stiffener and/or one of the transverse stiffeners protrudes from the module, thus facilitating the attachment of the photovoltaic module to a mounting structure (40).