Stretchable Photovoltaic Device with Corrugated Substrate

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Solution Overview

Problem

Conventional photovoltaic devices are rigid and unsuitable for applications requiring non-planar or arbitrary form factors, as they become inoperable when subjected to forces beyond their limited flexing or elongation/compression capabilities.

Innovation Solution

A stretchable photovoltaic device and module are developed, featuring a stretchable substrate with corrugations that allow photovoltaic cells to elongate or compress in response to applied forces, maintaining functionality across varying form factors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional rigid photovoltaic devices are used, then structural stability is maintained, but adaptability to non-planar forms and flexibility are lost

Engineering Contradiction:

Improveadaptability to non-planar formsVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The photovoltaic device is divided into multiple rigid PV cells that are electrically interconnected but mechanically separated by flexible interconnection elements and encapsulant materials. This segmentation allows each cell to maintain its rigid structure for stability while the interconnection elements provide flexibility for adaptability to non-planar forms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs flexible interconnection elements, encapsulant materials, and substrate structures that can bend and deform without damaging the rigid PV cells. These flexible components wrap around and connect the cells, enabling the overall device to conform to curved surfaces and non-planar geometries while maintaining structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If rigid construction is used to prevent damage to PV cells, then reliability is improved, but ease of operation on flexible surfaces deteriorates

Engineering Contradiction:

Improvereliability of PV cellsVSAvoidease of operation on flexible surfaces

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Flexible interconnection elements and encapsulant materials serve as intermediaries between the rigid PV cells and the flexible substrate or mounting surface. These intermediary components absorb mechanical stress and deformation, protecting the rigid cells from damage while enabling the device to be installed and operated on flexible or curved surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent utilizes materials and structures with varying mechanical properties - rigid PV cells for electrical stability and flexible interconnection elements with appropriate elasticity and bend radius parameters. By carefully selecting and controlling these physical parameters, the device achieves both reliability of the cells and ease of operation on flexible surfaces.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If photovoltaic cells are subjected to forces beyond their limited flexing capabilities, then adaptability to varying form factors increases, but reliability decreases due to damage and inoperability

Engineering Contradiction:

Improveadaptability to varying form factorsVSAvoidinoperability of PV cells

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The rigid PV cells are surrounded and protected by flexible encapsulant materials and interconnection elements that act as cushioning layers. These protective structures are designed beforehand to absorb and distribute mechanical forces, preventing direct transmission of excessive stress to the cells. This allows the device to adapt to varying form factors through controlled deformation of the cushioning materials without compromising cell reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 stretchable design enables photovoltaic devices to maintain performance and adapt to different shapes and forms, overcoming the rigidity limitations of traditional devices and enabling their use in applications that require flexible or curved surfaces.

Implementation Method 1

Pursuant to the PV effect, each of these renewable-energy sources ('PV source') generates energy, in the form of electricity, by harnessing electromagnetic radiation, such as sunlight

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

The stretchable part has a given length that is operable to change in response to a force being applied to the device

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10756226B2Photovoltaic device having a stretchable carrier

Publication Date: 2020.08.25 SUNLIGHT AEROSPACE INC

AI summary

A stretchable photovoltaic device, a stretchable photovoltaic module and a carrier for facilitating formation of a stretchable photovoltaic device and/or module are provided. The stretchable photovoltaic device includes a stretchable part, at least one photovoltaic cell and a surface over which that at least one photovoltaic cell is disposed. The stretchable part has a given length that is operable to change in response to a force being applied to the device. The given length may, for example, elongate when the force causes the device to elongate. Alternative and/or additionally, the given length may compress when the force causes the device to compress.