The optimization design of stress concentration areas in special-shaped photovoltaic module glass requires a multi-dimensional approach, encompassing geometry, material selection, processing technology, structural reinforcement, intelligent detection, and simulation, to reduce local stress peaks and improve overall structural reliability.
At the geometric optimization level, edge sharpening of the special-shaped photovoltaic module glass is a major cause of stress concentration. Introducing rounded corner transitions, gradient curved surfaces, or asymmetrical arc designs can effectively disperse stress. For example, flexible photovoltaic modules with a bending radius ≥300mm can be used in hyperbolic curved areas, achieving a smooth transition of the building's curved surface through modular splicing technology, avoiding stress concentration caused by abrupt changes in curvature. Simultaneously, a 1.2-meter-wide shade buffer zone can be set at the turning points of zigzag facades to reduce the risk of localized stress accumulation.
Regarding material selection, both optical performance and mechanical stability must be considered. Special-shaped photovoltaic module glass typically uses ultra-clear tempered glass, whose internal prestress can offset some external forces, but thinning the glass significantly reduces impact resistance. Therefore, while ensuring light transmittance, glass materials with good chemical stability and high tensile strength can be selected, or performance can be enhanced through composite structures. For example, a sandwich structure of 3.2mm tempered glass + 0.76mm PVB film + 3.2mm tempered glass can improve impact resistance and alleviate stress concentration through the elastic deformation of the PVB film.
Process optimization is a key aspect of reducing stress concentration. During cutting, the cutting speed and pressure of laser or waterjet cutting must be controlled to avoid microcracks or edge chipping. For irregular edges, CNC precision carving or chemical etching processes can be used to achieve a smooth transition. Furthermore, during tempering, heating temperature and cooling rate must be strictly controlled to ensure uniform thickness of the compressive stress layer on the glass surface and avoid internal stress imbalance caused by excessive temperature gradients.
Structural reinforcement technology can further enhance the stress concentration resistance of special-shaped photovoltaic module glass. At glass edges or stress concentration areas, metal reinforcing ribs or polymer support frames can be added to disperse local loads. For example, aluminum alloy profiles can be bonded to the back of hyperbolic curved glass components, achieving flexible connections through structural adhesive. This approach preserves the glass surface's curvature while enhancing overall rigidity. For large, irregularly shaped components, a double-glass thermal balance design can be employed, using an air or vacuum layer to isolate stress transmission and reduce the impact of thermal stress.
The introduction of intelligent detection technology provides data support for stress concentration optimization. Defect detection technology based on photoelasticity can monitor the stress distribution within the glass in real time, identifying high-stress areas through polarized light interference fringes. Combined with machine learning algorithms, the detection data can be rapidly analyzed to establish a stress concentration prediction model. Furthermore, acoustic emission sensors can capture microcrack propagation signals during stress application, enabling precise location of stress concentration areas.
Simulation technology is a crucial tool for optimized design. Numerical models of specially shaped photovoltaic module glass can be established through finite element analysis (FEM) to simulate stress distribution under different load conditions. Combined with topology optimization methods, the most rational stress distribution layout in the structure can be found, such as adding rounded corners or transition sections in stress concentration areas. Meanwhile, multiphysics coupling analysis can take into account the influence of environmental factors such as temperature, humidity, and wind pressure on stress concentration, providing a more comprehensive basis for design.
