Thin-Glass Polymer Photovoltaic Modules for Lightweight Impact Resistance
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Solution Overview
Problem
Conventional photovoltaic modules are heavy due to the use of thick glass and aluminum frames, which limits their application in lightweight and impact-resistant scenarios.
Innovation Solution
Replace thick glass with a combination of thin glass and polymer layers, using encapsulating materials with specific Young's moduli to maintain transparency and impact resistance, and reinforce the rear layer with high-modulus polymers and composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick glass and aluminum frames are used in conventional photovoltaic modules, then mechanical strength and impact resistance are improved, but weight increases significantly
Solution Approach 1:
The patent employs composite materials by combining polymer layers (such as PVF, PVDF, PET, or PC) with thin glass layers to replace the conventional thick glass and aluminum frame structure. This composite approach maintains mechanical strength and impact resistance while significantly reducing the overall weight of the photovoltaic module, enabling lightweight applications without sacrificing structural integrity.
Solution Approach 2:
The patent utilizes thin film structures, specifically polymer layers with thicknesses of 20-100 micrometers and thin glass layers of 0.5-2 millimeters, to replace bulky traditional materials. These thin films provide the necessary mechanical protection and structural support while dramatically reducing weight, allowing the module to achieve weight per unit area of less than 5 kg/m² or even 6 kg/m².
2Weight of stationary object
If thick glass is replaced with thin glass and polymer layers, then weight is reduced, but impact resistance may deteriorate
Solution Approach 1:
The patent uses composite material structures where polymer layers are combined with thin glass layers to compensate for the reduced thickness. The polymer layers (20-100 μm) provide flexibility and impact absorption, while the thin glass layers (0.5-2 mm) maintain rigidity and surface hardness, together achieving impact resistance comparable to or exceeding conventional thick glass modules.
Solution Approach 2:
The polymer layers serve as a cushioning element positioned between the thin glass layer and the photovoltaic cells. These polymer layers absorb and dissipate impact energy before it reaches the fragile photovoltaic cells, providing beforehand protection against hail and other impact events, thus maintaining impact resistance despite the use of thinner materials.
3Ease of manufacture
If conventional encapsulating materials are used, then manufacturing simplicity is maintained, but optical transparency and mechanical performance are compromised
Solution Approach 1:
The patent specifies precise parameter ranges for the encapsulating materials, including Young's modulus between 200-400 MPa and thickness between 20-100 micrometers. By controlling these parameters, the encapsulating material maintains optical transparency (allowing sufficient light transmission to photovoltaic cells) while providing adequate mechanical support and protection, balancing optical performance with structural requirements.
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
Achieves a lightweight photovoltaic module with improved impact resistance and durability, maintaining optical transparency and mechanical integrity, suitable for applications requiring low weight and robustness.
Implementation Method 1
photovoltaic cells disposed side by side and electrically connected to each other... intended to receive a luminous flux
Implementation Method 2
front layer of an encapsulating material and a rear layer of an encapsulating material... having a Young's modulus at 25° C. of strictly less than 50 MPa... having a Young's modulus at 25° C. of strictly greater than 150 MPa
Data Source
AI summary
The invention primarily relates to a photovoltaic module (1) obtained from a stack comprising: a first front layer (2); a plurality of photovoltaic cells (4); an encapsulating assembly (3) obtained by joining a front layer (3a) and a rear layer (3b) of an encapsulating material; a second rear layer (5). The first layer (2) comprises: a front layer made of a polymer material (2a); a front assembly (2b, 2c) comprising an interface front layer (2b) and a glass front layer (2c), with a thickness less than or equal to 2 mm, said front assembly (2b, 2c) being located between the polymer front layer (2a) and the encapsulating assembly (3), and the interface front layer (2b) being located between the polymer front layer (2a) and the glass front layer (2c). The front layer (3a) and the rear layer (3b) of an encapsulating material have a Young's modulus at 25° C. of strictly less than 50 MPa and of strictly greater than 150 Mpa, respectively.