Corrugated construction panels having embedded photovoltaic cells, and associated manufacturing processes

Abstract

Abstract A corrugated construction panel having embedded photovoltaic cells, including a corrugated base sheet, which can be used as a construction material panel, an adhesion array on the base sheet which includes cell adhesion regions located in photovoltaic placement zones in defined spatial relationships relative to peaks and troughs of the base sheet. Photovoltaic material is applied in each of the photovoltaic placement zones and wiring positioned to define electrical pathways between an input cable, an output cable and passing through the photovoltaic material sheets.

Description

FIELD OF THE INVENTION

[0001] The present invention relates, in various embodiments, to corrugated construction panels having embedded photovoltaic cells, and associated manufacturing processes. Various embodiments provide energy generating corrugated panels adapted for use as roofing materials, for example in a similar manner to conventional corrugated polycarbonate sheets. While some embodiments will be described herein with particular reference to that application, it will be appreciated that the invention is not limited to such a field of use, and is applicable in broader contexts. BACKGROUND

[0002] Any discussion of the background art throughout the specification should in no way be considered as an admission that such art is widely known or forms part of common general knowledge in the field.

[0003] Corrugated sheets (for example polycarbonate. Metallic, and those formed of other materials) are widely used and have substantial popularity as a roofing material, for example due to simplicity, durability, strength and rigidity. Conventionally, when a person wishes to install solar panels on a corrugated roof, the approach is to install the panels above the corrugated sheets. This is not ideal, for example taking away from the effectiveness and the aesthetic appeal of the corrugated sheets.

[0004] Attempts have been made to integrate solar sheets into corrugated roofing materials, for example as outlined in DE 102014106964. However, whilst such a concept may seem straightforward, there are significant technical challenges associated with forming a component in which solar sheets are sandwiched between corrugated sheets, for example in relation to solar sheet damage during formation. Such problems are implicitly noted in DE 102014106964, which illustrates examples in which solar sheets are sandwiched only between planar regions defined in corrugated sheets.

[0005] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. 2026201459   05 May 2026 SUMMARY OF THE INVENTION

[0006] Example embodiments are described below in the section entitled “claims”, and in the section entitled “detailed description”.

[0007] Reference throughout this specification to “one embodiment”, “some embodiments” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in some embodiments” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0008] As used herein, unless otherwise specified the use of the ordinal adjectives "first", "second", "third", etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

[0009] In the claims below and the description herein, any one of the terms comprising, comprised of or which comprises is an open term that means including at least the elements / features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed thereafter. For example, the scope of the expression a device comprising A and B should not be limited to devices consisting only of elements A and B. Any one of the terms including or which includes or that includes as used herein is also an open term that also means including at least the elements / features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

[0010] As used herein, the term “exemplary” is used in the sense of providing examples, as opposed to indicating quality. That is, an “exemplary embodiment” is an embodiment provided as an example, as opposed to necessarily being an embodiment of exemplary quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0012] FIG. 1A illustrates a panel according to one embodiment. 2026201459   05 May 2026

[0013] FIG. 1B illustrates a corrugated base sheet.

[0014] FIG. 1C illustrates the corrugated base sheet with adhesion regions in place.

[0015] FIG. 1D illustrates the corrugated base sheet with photovoltaic sheets and wiring in place.

[0016] FIG. 1E illustrates a manufacturing process.

[0017] FIGs. 2A to FIG. 2D illustrate a manufacturing setup for a progressive rolling process used during manufacture.

[0018] FIG. 3A illustrates a method according to one embodiment.

[0019] FIGs. 4A to FIG. 4C illustrate a progressive rolling process used during manufacture according to embodiments. DETAILED DESCRIPTION

[0020] The present invention relates, in various embodiments, to corrugated construction panels having embedded photovoltaic cells, and associated manufacturing processes. Various embodiments provide energy generating corrugated panels adapted for use as roofing materials, for example in a similar manner to conventional corrugated sheets formed of various materials (such as polycarbonate, steel, aluminium, bitumen fibre, fibre cement, and other materials). While some embodiments will be described herein with particular reference to that application, it will be appreciated that the invention is not limited to such a field of use, and is applicable in broader contexts.

[0021] In overview, embodiments of the present invention take the form of corrugated construction panels, for example suitable for use as roofing and wall coverings, with embedded photovoltaic cells. For example, sheets of flexible thin-film photovoltaic sheets are used, such as CIGS cells. These are sandwiched between a pair of corrugated sheets, for example conventional polycarbonate sheets (at least one of which having suitable light transmission properties). The corrugated sheets are bonded together using adhesives (optionally including double-sided tapes), which seal the photovoltaic sheets in an embedded manner (preferably hermetic sealing).

[0022] The technology described herein is specifically adapted to overcome technical challenges associated with the formation of components where thin-film photovoltaic sheets are sandwiched between a pair of corrugated sheets. For example, if such a component is formed using conventional techniques (for example thermal vacuum pressing techniques, as discussed in DE102014106964), 2026201459   05 May 2026 the photovoltaic sheets become damaged due to forces applied through the peaks and troughs. Overcoming such challenges has proven particularly problematic. The approach described herein relies on a combination approach which requires: (i) strategic placement of adhesives; and (ii) a progressive application process thereby to adhere a cover sheet to the boundary adhesion region along a direction normal to the axis of corrugation. This is described in greater detail further below.

[0023] A boundary surrounds the photovoltaic sheets (which may be split into multiple distinct zones), allowing for screws and / or other fixings to be inserted through the panel for the purposes of installation onto existing structures. For example, one embodiment provides a corrugated construction panel having a plurality of embedded photovoltaic sheets hermetically sealed between a base corrugated sheet and a cover corrugated sheet, wherein boundary regions between the sheets are configured to allow perforation to allow passage of fixings without affecting the hermetic sealing of the embedded photovoltaic sheets. In this manner, the panels are able to be used substantially in the same manner as conventional corrugated panels. Multiple photovoltaic embedded panels may be connected together as part of an interconnected solar system, for example using known coupling arrangements.

[0024] An example embodiment will now be described by reference to FIG. 1A to FIG. 1E. It will be appreciated that various aspects of this embodiment are design choices, and not intended to necessarily limit the scope of protection. FIG. 1A shows the constructed panel, FIG. 1B to FIG. 1E show the panel in a partially constructed form, and FIG. 1E shows a construction workflow.

[0025] The example embodiment takes the form of a corrugated construction panel 100 having a plurality of embedded photovoltaic cells 101.

[0026] The panel includes a corrugated base sheet 102 and a corrugated cover sheet 108 which sandwich and hermetically seal four photovoltaic sheets 101. These are thin sheets (for example 0.5mm to 1mm in thickness) with flexibility to conform to the corrugated shape. For example, strips of Miasole CIGS cells may be used, these being coupled together in an overlapping fashion to define sheets of the desired rectangular dimensions. For example, in one embodiment sheet dimensions are dimensions 45mm x 312mm, but larger sheets may be used. In some embodiments sheets are fabricated in the desired dimensions to negate or reduce the need to use multiple overlapped sheets.

[0027] Base sheet 102 (shown in isolation in FIG. 1B) is configured to be used as a construction material panel. For example, this may be a metallic sheet (for example ColorbondTM or the like), a polycarbonate sheet, or substantially any other form of corrugated material that is suitable for roofing (and / or similar) applications. 2026201459   05 May 2026

[0028] Cover sheet 108 is formed of a material with transparency appropriate to have acceptably low effects on solar transmission to the photovoltaic sheets. This is preferably a corrugated sheet with approximately the same dimensions as base sheet 102. In further embodiments cover sheet 108has an irregular shape and / or is formed from a plurality of individual sheet components which are arranged to cover and allow sealing of photovoltaic sheets 101.

[0029] For the purposes of manufacture and to enable sealing, an adhesion array is applied to the base sheet, as shown in FIG. 1C. This includes a boundary adhesion region 103 and a plurality of cell adhesion regions 105, 106.

[0030] Boundary adhesion region 103 defines boundaries of one or more photovoltaic placement zones 104. In the present example a single connected boundary adhesion region defines boundaries of four photovoltaic placement zones in a 2x2 array, to allow placement of sheets 101 as shown in FIG. 1A. In other embodiments the boundary adhesion region may be defined by separate subregions, which collectively define boundaries for the photovoltaic zone or zones. A key feature of the boundary adhesion region is that, when the panel is in a constructed form, hermetically seals photovoltaic sheets 101 between the base sheet 102 and cover sheet 108. Various forms of adhesives may be used. At present, a preferred adhesive is a double sided tape sold under the brand name ANKO, which has demonstrated advantageous performance in sealing with materials such as ColorbondTM and polycarbonate. However, other adhesives may be used, including various contact adhesives.

[0031] Cell adhesion regions 105, 106 are located in each of the photovoltaic placement zones. These photovoltaic adhesion regions are located in a defined spatial relationship relative to peaks and troughs defined by the base sheet. In the illustrated example, the defined spatial relationship includes positioning the cell adhesion regions 106 away from peaks defined by the corrugated sheet. This allows photovoltaic sheet 101 to be held in place and yet conform neatly into position upon rolling formation as described in more detail further below. One or more terminal regions 105 may be positioned at or proximal peaks, in some embodiments at a location corresponding to a leading edge of sheet 101 relative to a direction of rolling formation, thereby to hold that leading edge in place for the commencement of rolling.

[0032] A photovoltaic material sheet 101 is positioned in each photovoltaic placement zone. This is positioned such that the photovoltaic material sheet substantially conforms with the shape of the corrugations and is held in place by the photovoltaic adhesion regions. From a manufacturing perspective, this is preferably achieved via the progressive rolling application process described below. 2026201459   05 May 2026

[0033] Panel 100 also includes wiring components (e.g. insulated wires) which are configured to define an electrical pathway between: (i) an input cable with a connector member 110 that extends beyond the boundary adhesion region; and (ii) an output cable with a connector member 111 that extends beyond the boundary adhesion region; wherein the electrical pathway passes through the or each of the photovoltaic material sheets. Within the panel, insulated wires are preferably predominately retained in place between the base sheet and the cover sheet within boundary adhesion region 103.

[0034] Cover sheet 108 is coupled to the base sheet via boundary adhesion region 103. This coupling of the cover sheet to the base sheet via the boundary adhesion region results in the following properties: (i) Hermetic sealing of the or each photovoltaic material sheet in its respective photovoltaic placement zone; and (ii) Hermetic sealing around the input cable and the output cable at respective locations where they extend beyond the boundary adhesion region.

[0035] In the present embodiment, the boundary adhesion region defines boundaries of a plurality of photovoltaic placement zones; respective photovoltaic material sheets are applied to each of the photovoltaic placement zones; and following the progressive application process: the cover sheet collectively hermetically seals all of the photovoltaic material sheets; and wires interconnecting the photovoltaic material sheets that form part of the electrical pathway are secured in place between the boundary adhesion region and the cover sheet.

[0036] The manufacturing of panel 100 is preferably achieved via a method as described below.

[0037] The method essentially begins with a corrugated base sheet, which is configured to be used as a construction material panel. The adhesion array is defined on the base sheet to define the boundary adhesion regions and the cell adhesion regions. A photovoltaic material sheet is then positioned in each photovoltaic placement zone, such that the photovoltaic material sheet substantially conforms with the shape of the corrugations and is held in place by the photovoltaic adhesion regions. Wiring is then positioned to define the electrical pathway.

[0038] With the cells and wiring in place, a progressive application process is performed thereby to adhere the cover sheet to the boundary adhesion region. This process progressively presses the cover sheet to the base sheet along a direction normal to the axis of corrugation of the base sheet (e.g. left to right relative to the diagrams in FIG. 1A to 1D). Example equipment used for this process is shown in FIG. 2A to FIG. 2D. Such a progressive rolling process along a direction normal to the 2026201459   05 May 2026 axis of corrugation is advantageous in relation to achieving close profiling of the base sheet, photovoltaic sheets, and the cover sheet, whilst avoiding damage to the photovoltaic sheets. This is further facilitated by the positioning of the cell adhesion regions predominantly in corrugation troughs (as opposed to throughout the photovoltaic placement zones). This results in elongate regions of the base sheet, parallel to the axis of corrugation, in which photovoltaic adhesion regions are absent. These regions, which are adhesive free regions spaced apart along an axis normal to the axis of corrugation, prevent stressing of the photovoltaic sheets during the progressive application process. This overcomes issues experienced where there is an attempt to seal photovoltaic sheets via sandwiching.

[0039] For the purposes of the progressive rolling process, the edge of the top sheet should be held up on one side (so the two sheets cannot touch) whilst the other edge is aligned and clamped to the mating edge of the bottom sheet, prior to the progressive rolling of the sheets into the troughs and over the peaks so they touch and adhere incrementally. This facilitates a process which prevents the top sheet catching on sticky areas and / or stretching the solar sheet, and / or leading to the formation of air gaps (and risk of delamination).

[0040] The progressive rolling process is optionally followed by a compression and / or vacuum process thereby to better reinforce sealing properties.

[0041] It will be appreciated that the formed panel is particularly well suited for construction purposes, noting that there is ample space across the overall area (except in the cell adhesion zones) through which attachment holes may be formed for the purposes of construction (e.g. screws drilled through). This occurs in areas where the boundary adhesion inherently maintains hermetic sealing of photovoltaic and wiring components even in spite of the formation of such attachment holes.

[0042] In a further embodiment a panel includes: a first corrugated sheet; a second corrugated sheet; and one or more flexible thin-film photovoltaic sheets. The one or more flexible thin-film photovoltaic sheets are positioned relative to the first corrugated sheet thereby to define:

[0043] (i) one or more photovoltaic zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets overlie the first corrugated sheet; and

[0044] (ii) one or more boundary zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets do not overlie the first corrugated sheet, wherein the one or more boundary zones provide a peripheral boundary for each of the one or more photovoltaic zones.

[0045] The first corrugated sheet is bound to the second corrugated sheet such that the second corrugated is adhered in a manner which: (a) binds the photovoltaic zones to the second corrugated 2026201459   05 May 2026 sheet; and (b) seals the photovoltaic zones via binding of the second corrugated sheet to the first corrugated sheet at the boundary zones.

[0046] An example panel formation method 300 is illustrated in FIG. 3. The method commences at block 301 with providing a first corrugated sheet. This may, for example be a polycarbonate or Colourbond sheet, although other materials may be used.

[0047] Block 302 represents a process including overlapping one or more flexible thin-film photovoltaic sheets on the first corrugated sheet. This is performed thereby to define: (i) one or more photovoltaic zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets overlie the first corrugated sheet; and (ii) one or more boundary zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets do not overlie the first corrugated sheet, wherein the one or more boundary zones provide a peripheral boundary for each of the one or more photovoltaic zones.

[0048] In some embodiments, block 302 includes forming one or more apertures thereby to facilitate later coupling of one or more of the photovoltaic sheets to a connector for coupling to other components (e.g. further panels). However, as per examples illustrated and discussed above, this is not necessary. It will be appreciated that the construction methods taught herein allow for holes to be drilled through boundary zones of fully formed panels without affecting solar power generation components.

[0049] The flexible thin-film photovoltaic sheets may be, for example, CIGS cells (for instance as available commercially from companies such as MiaSole Hi-Tech Corp). However, those skilled in the art will recognise various thin film products suitable for the present purposes. In some cases multiple cell sheets are coupled (e.g. overlapped) for the purposes of each of the photovoltaic zones.

[0050] Block 303 represents a process including electrically coupling the cells of distinct photovoltaic zones. For example, wires are used as described further above.

[0051] Block 304 represents a process including application of adhesive to the first sheet (with overlaid photovoltaic sheets). This may be a two sided tape as described further above. This may alternately be a contact / spray adhesive such as a synthetic polymer adhesive such as Sikabond sprayfix construction adhesive (or other similarly adapted adhesive) , optionally used to cover the entire surface. This is not intended to adhere the photovoltaic sheets to the first corrugated sheet -these remain loosely in place.

[0052] Block 305 represents providing a second corrugated sheet. The second corrugated sheet has length and width dimensions greater than sufficient to overlap the one or more photovoltaic 2026201459   05 May 2026 zones. In alternate embodiments multiple second corrugated sheets are used, with one applied to cover each of the photovoltaic zones separately. It will be appreciated that the second sheet should be formed of a material which allows relatively uninhibited light penetration (thereby to facilitate generation of solar energy via the photovoltaic sheets).

[0053] Block 306 represents an optional application of further contact adhesive, this time to the second sheet. This is typically only relevant where a spray adhesive is used (as opposed to a double sided tape).

[0054] Block 307 represents a rolling process thereby to bind the second corrugated sheet to the first corrugated sheet. This is performed such that the second corrugated sheet is sealingly adhered to the first corrugated sheet in the boundary zones of the first corrugated sheet, and adhered to the one or more photovoltaic zones of the first corrugated sheet, thereby to form the panel.

[0055] The rolling process provides for progressive contacting of the first and second panels, along a direction normal to the axis of corrugation. An example rolling process is illustrated in FIG. 4A and 4B. The rolling process includes: (i)    Contacting an edge zone of a sheet 401 to a corresponding edge zone of the first 402, such that the sheets’ respective corrugations substantially align proximal the edge zones. This is shown in FIG. 4A, with the respective edge zones contacting at region 430. (ii)   Applying compressive pressure via an elongate member 431 at or adjacent the edge zones, wherein the elongate member is configured with its axis parallel with the corrugations of the first and second corrugated strips. (iii)   Progressively rolling elongate member 431 in a direction normal to the axis of corrugations (line 432) thereby to progressively compressively adhere the second corrugated sheet to the first corrugated sheet and seal in place the photovoltaic zones 202. Due to the way in which adhesives are applied, the thin-film photovoltaic sheets are able to move into place during the rolling process.

[0056] It should be appreciated that the second corrugated sheet is bent during the rolling process between FIG. 4A and FIG. 4B thereby to facilitate progressive engagement and avoid damaging the photovoltaic materials. In an alternate approach, shown in FIG. 4C, both sheets are initially outwardly curved, and rolled together progressively in a direction normal to the axis of corrugations. 2026201459   05 May 2026

[0057] As such, the second corrugated sheet becomes adhered in a manner which: (a) binds the photovoltaic zones to the second corrugated sheet; and (b) seals the photovoltaic zones via binding of the second corrugated sheet to the first corrugated sheet at the boundary zones.

[0058] Following the rolling process, the formed panel is subjected to a pressing process, as represented by block 308. In this process, the formed panel is pressed (for example using a hydraulic press) between matching corrugated upper and lower bed members having length and width dimensions at least equal to the formed panel, thereby to remove air pockets between the sheets and encourage adhesive binding. At least one of the upper and lower bed members is heated, with preferably both being heated. The pressing process is operated at a predefined pressure and temperature, thereby to encourage robust bonding, and remove air pockets between the corrugated sheets. It will be appreciated that the predefined pressure should be limited so as not to damage the photovoltaic sheets.

[0059] Block 309 represents a process including configuring a sealed electrical coupling with one of the thin-film photovoltaic sheets, thereby to facilitate external electrical coupling of the panel to a further component. For example, this aperture may be configured to access a coupling member provided on one of the photovoltaic sheets, and following coupling via a connector member, the aperture is sealed thereby to prevent / minimise water ingress.

[0060] The practical installation of the photovoltaic embedded panels generally follows conventional processes for installation of regular corrugated panels, with the limitation that screws / fixings are only inserted through the photovoltaic panels at the boundary zones. These are ideally visibly marked on the outer surface of the first and / or second corrugated panels (e.g. via printed and / or adhesive markings, and / or due to visibility of solar components).

[0061] It will be recognised that the above embodiments provide for solar power generation to be achieved via corrugated construction panels, for example panels suitable for application in roofing and other applications. Use of corrugated panels has a range of advantages, both in terms of: (i) inherent advantages of corrugated panels known in the building industry; and (ii) power generation advantages given the extent to which solar exposure remains effective across a wider range of sun positions (compared to a stationary planar panel).

[0062] It should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, FIG., or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects 2026201459   05 May 2026 lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

[0063] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those skilled in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0064] Furthermore, some of the embodiments are described herein as a method or combination of elements of a method that can be implemented by a processor of a computer system or by other means of carrying out the function. Thus, a processor with the necessary instructions for carrying out such a method or element of a method forms a means for carrying out the method or element of a method. Furthermore, an element described herein of an apparatus embodiment is an example of a means for carrying out the function performed by the element for the purpose of carrying out the invention.

[0065] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0066] Similarly, it is to be noticed that the term coupled, when used in the claims, should not be interpreted as being limited to direct connections only. The terms "coupled" and "connected," along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Thus, the scope of the expression a device A coupled to a device B should not be limited to devices or systems wherein an output of device A is directly connected to an input of device B. It means that there exists a path between an output of A and an input of B which may be a path including other devices or means. "Coupled" may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other but yet still co-operate or interact with each other.

[0067] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as falling within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added 2026201459   05 May 2026 or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

Claims

1. A method of manufacturing a corrugated construction panel having embedded photovoltaic cells, the method including:providing a corrugated base sheet, which is configured to be used as a construction material panel;defining an adhesion array on the base sheet, wherein the adhesion array includes:(i) a boundary adhesion region, wherein the boundary adhesion region defines boundaries of one or more photovoltaic placement zones,(ii) a plurality of cell adhesion regions located in each of the photovoltaic placement zones, wherein the photovoltaic adhesion regions are located in a defined spatial relationship relative to peaks and troughs defined by the base sheet, wherein the defined spatial relationship results in elongate regions of the base sheet parallel to the axis of corrugation in which photovoltaic adhesion regions are absent;applying a photovoltaic material sheet in the or each photovoltaic placement zone, such that the photovoltaic material sheet substantially conforms with the shape of the corrugations and is held in place by the photovoltaic adhesion regions;positioning wiring thereby to define an electrical pathway between: (i) an input cable that extends beyond the boundary adhesion region; and (ii) an output cable that extends beyond the boundary adhesion region; wherein the electrical pathway passes through the or each of the photovoltaic material sheets; andperforming a progressive application process thereby to adhere a cover sheet to the boundary adhesion region, wherein the progressive application process progresses along a direction normal to the axis of corrugation of the base sheet, thereby to:(i) hermetically seal the or each photovoltaic material sheet in its respective photovoltaic placement zone;(ii) hermetically seal around the input cable and the output cable at respective locations where they extend beyond the boundary adhesion region; and(iii) closely conform corrugations in the cover sheet to corrugations in the base sheet thereby to sandwich the or each photovoltaic material sheet in its respective photovoltaic placement zone.2026201459   05 May 20262. A method according to any preceding claim wherein the defined spatial relationship includes positioning the cell adhesion regions away from peaks defined by the corrugated sheet.

3. A method according to any preceding claim wherein either or both of the boundary adhesion regions and the photovoltaic adhesion regions are defined by a double-sided adhesive tape.

4. A method according to any preceding claim wherein: (i) the boundary adhesion region defines boundaries of a plurality of photovoltaic placement zones; (ii) respective photovoltaic material sheets are applied to each of the photovoltaic placement zones; (iii) following the progressive application process, the cover sheet collectively hermetically seals all of the photovoltaic material sheets; and (iv) wires interconnecting the photovoltaic material sheets that form part of the electrical pathway are, following the progressive application process, secured in place between the boundary adhesion region and the cover sheet.

5. A corrugated construction panel having embedded photovoltaic cells formed by a method according to any preceding claim.

6. A corrugated construction panel having embedded photovoltaic cells, the panel including:a corrugated base sheet, which is configured to be used as a construction material panel;an adhesion array on the base sheet, wherein the adhesion array includes:(i) a boundary adhesion region, wherein the boundary adhesion region defines boundaries of one or more photovoltaic placement zones,(ii) a plurality of cell adhesion regions located in each of the photovoltaic placement zones, wherein the photovoltaic adhesion regions are located in a defined spatial relationship relative to peaks and troughs defined by the base sheet, wherein the defined spatial relationship results in elongate regions of the base sheet parallel to the axis of corrugation in which photovoltaic adhesion regions are absent;a photovoltaic material sheet in the or each photovoltaic placement zone, positioned such that the photovoltaic material sheet substantially conforms with the shape of the corrugations and is held in place by the photovoltaic adhesion regions; andwiring thereby to define an electrical pathway between: (i) an input cable that extends beyond the boundary adhesion region; and (ii) an output cable that extends beyond the boundary adhesion region; wherein the electrical pathway passes through the or each of the photovoltaic material sheets;2026201459   05 May 2026a cover sheet coupled to the base sheet via the boundary adhesion region;wherein the coupling of the cover sheet to the base sheet via the boundary adhesion region:(i) hermetically seals the or each photovoltaic material sheet in its respective photovoltaic placement zone; and(ii) hermetically seals around the input cable and the output cable at respective locations where they extend beyond the boundary adhesion region;wherein the coupling of the cover sheet to the base sheet is achieved via progressive application process thereby to adhere a cover sheet to the boundary adhesion region, wherein the progressive application process progresses along a direction normal to the axis of corrugation of the base sheet.

7. A panel according to claim 6 wherein the defined spatial relationship includes positioning the cell adhesion regions away from peaks defined by the corrugated sheet.

8. A panel according to claim 6 or claim 7 wherein either or both of the boundary adhesion regions and the photovoltaic adhesion regions are defined by a double-sided adhesive tape.

9. A panel according to any one of claims 6 to 8 wherein: (i) the boundary adhesion region defines boundaries of a plurality of photovoltaic placement zones; (ii) respective photovoltaic material sheets are applied to each of the photovoltaic placement zones; (iii) the cover sheet collectively hermetically seals all of the photovoltaic material sheets; and (iv) wires interconnecting the photovoltaic material sheets that form part of the electrical pathway are secured in place between the boundary adhesion region and the cover sheet.

10. A corrugated construction panel having a plurality of embedded photovoltaic sheets hermetically sealed between a base corrugated sheet and a cover corrugated sheet, wherein boundary regions between the sheets are configured to allow perforation to allow passage of fixings without affecting the hermetic sealing of the embedded photovoltaic sheets.

11. A method of manufacturing a corrugated construction panel having embedded photovoltaic cells, the method including:providing a first corrugated sheet;overlapping one or more flexible thin-film photovoltaic sheets on the first corrugated sheet, thereby to define:2026201459   05 May 2026(i) one or more photovoltaic zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets overlie the first corrugated sheet; and(ii) one or more boundary zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets do not overlie the first corrugated sheet, wherein the one or more boundary zones provide a peripheral boundary for each of the one or more photovoltaic zones;providing a second corrugated sheet, wherein the second corrugated sheet has length and width dimensions greater than sufficient to overlap the one or more photovoltaic zones;performing a progressive application process thereby to adhere a cover sheet to the boundary adhesion region, wherein the progressive application process progresses along a direction normal to the axis of corrugation of the base sheet, wherein the progressive application process is a rolling process thereby to sandwich the photovoltaic sheets between the first corrugated sheet and the second corrugated sheet, and sealingly adhering the first corrugated sheet in the boundary zones of the first corrugated sheet thereby to form a panel in which the photovoltaic sheets are hermetically sealed;wherein the rolling process includes:(i) contacting an edge zone of the second corrugated sheet to a corresponding edge zone of the first corrugated sheet, such that the sheets’ respective corrugations substantially align proximal the edge zones;(ii) applying compressive pressure via an elongate member at or adjacent the edge zone, wherein the elongate member is configured with its axis parallel with the corrugations of the first and second corrugated sheets;(iii) progressively rolling the elongate member in a direction normal to the axis of corrugations thereby to progressively compressively apply the second corrugated sheet to the first corrugated sheet and the photovoltaic zones, wherein the thin-film photovoltaic sheets are able to move relative to the first and / or second corrugated sheet during the rolling process;such that the second corrugated sheet becomes adhered in a manner which: (a) sandwiches the photovoltaic zones between the first and second corrugated sheets; and (b) seals the photovoltaic zones via binding of the second corrugated sheet to the first corrugated sheet at the boundary zones.2026201459   05 May 202612. A method according to claim 11 wherein the step of overlapping one or more flexible thin-film photovoltaic sheets on the first corrugated sheet is performed without adhering the overlapping one or more flexible thin-film photovoltaic sheets to the first corrugated sheet.

13. A method according to claim 11 or claim 12 wherein following overlapping of the one or more flexible thin-film photovoltaic sheets on the first corrugated sheet, contact adhesive is applied to the exposed areas of the one or more photovoltaic zones and the one or more boundary zones.

14. A method according to any one of claims 11 to 13 including, prior to the rolling process, applying contact adhesive to the second sheet at regions which, during rolling, contact with the one or more boundary zones but not the one or more photovoltaic zones.

15. A method according to any one of claims 11 to 14 wherein, following the rolling process, the formed panel is pressed between a matching corrugated upper lower bed members having length and width dimensions at least equal to the formed panel, thereby to remove air pockets between the sheets and encourage adhesive binding.

16. A method according to claim 15 wherein at least one of the upper and lower bed members is heated.

17. A method according to claim 15 wherein the pressing is facilitated by a hydraulic press at a predefined pressure and temperature.

18. A method according to any one of claims 11 to 17 wherein there are two or more distinct photovoltaic zones, and the method includes, prior to the rolling process, coupling the photovoltaic zones in series via connective wires.

19. A corrugated construction panel formed via a method according to any one of claims 11 to 18.

20. A corrugated construction panel having embedded photovoltaic cells, the panel including:a first corrugated sheet;a second corrugated sheet;one or more flexible thin-film photovoltaic sheets;2026201459   05 May 2026wherein the one or more flexible thin-film photovoltaic sheets are positioned relative to the first corrugated sheet thereby to define:(i) one or more photovoltaic zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets overlie the first corrugated sheet; and(ii) one or more boundary zones, being zones where the regions of the one or more flexible thin-film photovoltaic sheets do not overlie the first corrugated sheet, wherein the one or more boundary zones provide a peripheral boundary for each of the one or more photovoltaic zones;wherein, during manufacture, the thin-film photovoltaic sheets are sandwiched between the first corrugated sheet and the second corrugated sheet via a progressive application process along a direction normal to the axis of corrugation of the base sheet, wherein the progressive application process progresses along a direction normal to the axis of corrugation of the base sheet.

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