UV Exposure Chamber for PV Modules Using Vertical Lamp Arrays
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Solution Overview
Problem
Existing UV exposure test equipment for photovoltaic modules is inadequate for high-volume manufacturing, with issues of exposure uniformity and floor space requirements, leading to compromised test quality and increased costs.
Innovation Solution
A UV exposure apparatus with a vertically oriented array of lamps and reflective panels around the exposure area, optimizing exposure uniformity and reducing floor space requirements through the use of multiple target planes and strategically positioned reflectors to enhance irradiance uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If modules are loaded horizontally onto a test table with over-hanging UV lamps, then the exposure setup is simple, but floor space requirements increase significantly
Solution Approach 1:
The patent transitions from horizontal module loading to vertical module loading, changing the spatial dimension of the exposure chamber. Modules are positioned vertically on target planes that can rotate, allowing the chamber to occupy less floor space while maintaining exposure effectiveness through multi-angle UV lamp illumination.
2Manufacturing precision
If exposure area is over-sized to compensate for poor uniformity, then exposure uniformity improves, but cost per sample tested increases
Solution Approach 1:
The patent introduces dynamic elements including rotatable target planes that can rotate to different angles, and UV lamps positioned at multiple angles that can be independently controlled. This dynamic configuration allows the system to achieve uniform exposure across the module surface without requiring an oversized exposure area, thereby reducing cost per sample while maintaining exposure uniformity.
3Productivity
If more UV lamps are added to increase exposure intensity, then throughput improves, but floor space and device complexity increase
Solution Approach 1:
The patent employs a nested configuration where multiple UV lamps are arranged in concentric circles or arrays around the vertical module target planes. This nested arrangement allows multiple light sources to be compactly positioned in three-dimensional space, increasing exposure intensity and throughput without proportionally increasing floor space requirements.
4Productivity
If vertical orientation with multiple target planes is used, then floor space is reduced and throughput increases, but exposure uniformity becomes more difficult to achieve
Solution Approach 1:
The patent applies local quality by positioning UV lamps at specific angles and locations relative to each target plane, with independent control of lamp intensity and target plane rotation. This localized optimization ensures that each vertical target plane receives uniform exposure from the multi-angle lamp array, maintaining exposure uniformity while achieving high throughput through multiple simultaneous test positions.
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 apparatus achieves superior exposure uniformity and increased throughput while minimizing floor space, allowing for efficient testing of multiple PV modules with improved irradiance distribution and reduced costs.
Implementation Method 1
exposure to ultraviolet (UV) radiation in sunlight, specifically in the UVA (320-400 nm) and UVB (280-320 nm) wavelength ranges
Implementation Method 2
panels reflective to UV radiation positioned around the sides of the exposure area
Data Source
AI summary
An apparatus for performing UV light exposure testing of solar panels, also known as PV modules, with superior exposure uniformity, equipment throughput, and floor space requirements, consisting of a chamber including a plurality of UV lamps in a lamp array, at least one target plane, and reflective panels positioned within the chamber to redirect UV light to the target plane(s).