Mechanical performance analysis of the lightweight semi-flexible photovoltaic module

The mechanical performance of a lightweight photovoltaic (PV) module plays a more central role than that of a conventional PV module because it is more prone to causing microcrack. In this study, three types of lightweight semi-flexible PV modules, namely three-layer glass fiber prepreg tape module (SMS module), polyethylene terephthalate module (CPC module), and acrylic glass fiber-reinforced composite module (US module), were designed. Tensile and flexural tests were first conducted to compare their mechanical properties. Then, an experimental-based constitutive equation was derived and incorporated into a finite element method (FEM) model. Finally, the applicability of laminated-plate theory to the proposed PV module was assessed. Results show that the SMS module exhibited exceptional mechanical performances; its tensile strength was 1.4 times that of the US module and 1.8 times that of the CPC module, its flexural strength exceeded the US module by 20 % and the CPC module by 50 %. A five-support configuration along the short edge, which balanced load-bearing and cost, was identified as the optimal choice. Despite experiencing the highest stress under temperature fluctuations, the SMS module exhibited the lowest deflection because of its superior mechanical performances; its maximum deflection was reduced by 35 % and 49 % compared to the US and CPC modules, respectively. Compared to FEM results, the laminated-plate theory underestimated stress and deflection variations with average errors of 35 % and 40 %.