Lightweight photovoltaic module blocks.

Abstract

A design device for specific lightweight photovoltaic modules using polymer foams that are both lightweight and rigid enough to meet all technical requirements and specifications, and even to provide new functionalities, new possibilities, new installation methods, thus contributing to a wider deployment of this renewable energy.

Description

Title of the invention: Lightweight photovoltaic module block. Technical field

[0001] The present invention relates to a specific design of lightweight photovoltaic modules which allows new possibilities of use, new modes of installation and which thus contributes to a wider deployment of these renewable energy generators. Prior art

[0002] Photovoltaic modules, or photovoltaic solar panels, are designed to generate a direct electric current when exposed to solar radiation. They typically consist of a transparent front face made of glass or polymer materials, allowing a maximum amount of light to pass through. At the heart of the modules is the part of the photovoltaic reactive elements encapsulated in a polymer material, all connected by electrical connections leading to a junction box which ensures the output of the electrical cables. At the rear is an insulating material, most often made of polymer; the whole forming a photovoltaic "laminate".

[0003] To ensure the maintenance, rigidity and strength of the laminate, there are two main design axes: Either these laminates are surrounded on their periphery by a resistant frame, most often in aluminum. Or, more marginally, they can be designed to be used directly without a frame. In this specific case, they are intended to be glued directly onto a sufficiently rigid support to guarantee their mechanical resistance (for example on roofing elements or building facades, etc.).

[0004] All photovoltaic modules are designed to guarantee good performance over the years. They have physical and mechanical electrical specifications corresponding to the standards in force (such as for example the IEC-61215 IEC-61730 standards). Typically, this normative framework includes minimum requirements for resistance to environmental constraints such as wind, snow, moisture intrusion, heat, shocks as well as safety requirements, particularly on the electrical side. All of this influences the materials, the sizing of the parts and the design options chosen by the module manufacturers.

[0005] These requirements also induce constraints in the installation of the modules with various fixing systems or structures; Constraints also in terms of weight, in terms of total overload of the device, and possibly also on the positioning of fixing points, and the need to make holes in the installation supports or even to ballast the installation structure. All this can complicate, limit or even exclude the installation of photovoltaic systems.

[0006] An example of delicate implementation is that of large roofs where the static resistance of the structure does not allow the addition of systems that are too heavy (typically between 12 and 15 kg per m2).

[0007] Thus, manufacturers of photovoltaic modules are looking for solutions for lighter systems that integrate all or part of the components or structures of installations. This is all while guaranteeing satisfactory levels of solidity, maneuverability and durability. The solutions envisaged must remain competitive and, if possible, offer a good recyclability rate. Brief description of the drawings

[0008] Here is the list of diagrams and illustrations located at the end of the document.

[0009] - [Fig.l] represents a simplified diagram of a photovoltaic module block seen from face then in side section.

[0010] Caption:

[0011] 1: Photovoltaic laminate

[0012] 2: Support part of the block in polymer material

[0013] 3: The support for installing the photovoltaic module blocks (roofs, floors, etc.)

[0014] - [Fig.2] represents a top view then a side sectional view of an ins installation of block modules in simple solar exposure.

[0015] - [Fig.3] represents a horizontal front view of a series of five block modules interconnected on a flat support.

[0016] - [Fig.4] represents a top view then a side sectional view of an ins installation of block modules in double exposure (for example East-West).

[0017] - [Fig.5] represents a front and then side sectional view of an example of a block- module designed with a specific option to improve water flow in the lower part.

[0018] - [Fig.6] represents a front sectional view of a module block drawn with a specific option to improve the ventilation of the laminate.

[0019] - [Fig.7] represents a top view of an example of block modules drawn with an inter-nesting option.

[0020] - [Fig.8] represents a block diagram of a version of the module block without in proper inclination. Here a side section and two front views in perspective, one in portrait configuration and the other in landscape.

[0021] - [Fig.9] represents a side view of four block modules without inclination glued to an inclined support. Summary of the invention

[0022] Here we develop the design of a reinforced photovoltaic module block in back side of the photovoltaic laminate, thanks to the use of a block of expanded or crosslinked polymer foam. The type of polymer foam chosen can vary but it can be made for example of expanded polypropylene EPP or PPE, expanded polyurethane, expanded PVC, expanded polyethylene PE or LDPE, polystyrene PS, if possible it can also be based on biomaterials or biosourced materials etc.

[0023] To obtain the desired shapes, this polymer rear support part can be thermo-molded or thermoformed and / or cut or even made from solidified liquid foams. These materials are generally available in several density grades. Decisions on densities will be made according to the objectives of strength and rigidity while maintaining maximum possible lightness, also depending on costs, applications and the desired properties.

[0024] These materials listed here are accessible, competitive, lightweight and more or less resistant to multiple climatic constraints such as rain, UV, fire, and mechanical constraints such as pressure and shock. Many of them are already used in the construction and building sector and in many applications of everyday objects.

[0025] To constitute this support part of the module blocks, it may also be envisaged to use a combination of materials with, for example, an outer part or "envelope", more resistant to shocks and UV rays, and an inner part or "core", made of a less dense but lighter material. In this context, it could be imagined that the envelope is made of a polymer material, but possibly also of a metallic material such as aluminum, zinc, steel or combinations of metallic materials, possibly even covered with a protective paint or varnish.

[0026] Description of the elements of the photovoltaic module thus designed:

[0027] A photovoltaic module is made up of a part called "photovoltaic laminate" because they are most often assembled via the lamination technique combining heat and air vacuum. On the front face or external face exposed to solar radiation, these laminates are made up of a transparent layer of glass or polymer / composite materials of varying thickness. Under this protective layer we find the sensitive photovoltaic part and the electrical connections encapsulated in a suitable material such as EVA. This active part can be of various technologies, using photo-reactive semiconductor materials of all types: Silicon Cells (c-Si), active layers based on CIGS, CDTE, Perovskite, OPV, etc. The electrical connections at the heart of the laminates can be of all types or configurations but they run towards connection boxes from which the electrical cables leave outside the modules.The back side is typically . made of an insulating and protective film made of synthetic material, often based on Tedlar (TPT, TPA, but also APA, PO, KPE (PVDF-PET-EVA etc).

[0028] It is on this rear face that we stick, or heat-stick, or heat-weld, the polymer support part. This can be of various shapes depending on the intended uses (see the illustrations). This support part can itself be glued to the existing support in the installation environment of the photovoltaic system and for the entire duration of its operation (typically twenty years or more). These module blocks can also be maintained or fixed by more classic and common installation devices or structures, such as clamps, hooks, reclosers or aluminum profiles for example. The connection boxes can be installed traditionally: glued or heat-sealed on the laminated part of the modules, most often on the rear face.

[0029] These newly created photovoltaic modules that we call "Module blocks" will in turn have to pass the tests and certifications in force before their installation. In certain cases, these tests and certifications will have to be considered specifically in connection with an installation support. Advantages of the process:

[0030] Several advantages arise from the implementation of this innovative design and the use of polymer in the production of this support part of the module blocks:

[0031] This support part ensures its mechanical strength and rigidity for the entire photovoltaic module block, which makes it possible to dispense with a peripheral frame. This desired rigidity is adjustable depending on the materials used, particularly their density. Thus, it may be possible to consider reducing the thickness of the transparent front protective face, made of glass or polymer / composite, and thus gain in lightness while maintaining resistance to hail-type impacts.

[0032] This support part allows the module blocks to offer suitable shapes so that they are best positioned on flat or inclined installation supports, ensuring the ideal slope and inclination chosen for the exposed face of the photovoltaic laminate. The design of the support part may, for example, offer an ideal inclination for the desired solar exposure, typically a single exposure (Cf. [Fig.2] and 3). or a double exposure (east / west for example) by associating the module blocks back to back (Cf. [Fig.4]).

[0033] This design allows the development of specific shapes or passages for water runoff around the module blocks positioned on their various possible installation supports (Cf. [Fig.5]).

[0034] This design allows the development of specific shapes or air passages for ventilation from the rear of photovoltaic laminates (Cf. [Fig.6]).

[0035] This design allows the development of shapes for nesting blocks within each other to form a mesh of physically interconnected block modules (see [Fig.7]). This nesting system is useful for facilitating installation and for strengthening wind resistance.

[0036] This design allows the development of extremely simple, space-saving and economical photovoltaic module blocks in a flat configuration (Cf. [Fig.8] and 9)

[0037] This design also allows the development of shapes for the passage of electrical cables around the photovoltaic module blocks to allow the organization and maintenance over time of these cables, which are essential for all photovoltaic systems. Non-limiting examples of implementation:

[0038] Below is a list of contexts for installing photovoltaic systems for which this innovation can provide a positive response.

[0039] - In the case of large roofs with steel tray covering: it will be possible to glue module blocks specifically cut on the roof, after checking for good adhesion. We can imagine a simple, rather southern, exposure, or a double, rather east-west exposure.

[0040] - In the case of low-sloped roofs covered with a waterproofing membrane, especially for buildings that cannot accept large additional loads. When renovating the roof and installing a new membrane, the module blocks can be glued to the new roof. Note that the gluing technique will have been validated and certified beforehand. In this case, we can imagine a simple, rather southern exposure, or a double exposure, east-west.

[0041] - In the case of building facades, the shape of the block modules can be adapted for ideal positioning depending on solar radiation and the chosen architecture. In this configuration, the block-module polymer foam support part can constitute an additional layer of thermal insulation for the building.

[0042] - In the case of installation of ground-mounted photovoltaic power plants, on structures of dedicated installations: the module blocks designed in this way can replace the use of conventional modules with their aluminum frames. There will be a saving on production costs and possibly also on the carbon or energy balance of the installation.

Claims

Claims

1. Design of photovoltaic module block for which a photovoltaic laminate is associated by gluing on the rear face, on a so-called support part made of expanded or crosslinked polymer foam, which is characterized by the fact that the photovoltaic laminate is thus supported on a majority part of its rear surface. This polymer material may consist, for example, of expanded polypropylene EPP or PPE, expanded polyurethane, expanded PVC, expanded polyethylene PE or LDPE, expanded polystyrene PS, or any other expanded synthetic polymer materials; it may also consist of biomaterials or biosourced materials.If the core of this support part can be made of polymer foam as described above, it could possibly also be designed with a combination of several materials with the core or the interior of the part in expanded polymer foam, but covered by an outer protective envelope in a material more resistant to shocks and ultraviolet rays such as a metallic material, another polymer, or even the same polymer but in a higher density. To obtain the desired shapes, this support part could, depending on the manufacturing processes, be thermo-molded, thermoformed, cut, 3D printed, or even designed from solidified liquid foams.

2. Design according to claim 1, for which the shape of the support part of the module block may have a slope or an inclination of the photovoltaic laminate to optimize the runoff of rainwater and solar exposure.

3. Design according to any one of the preceding claims, for which the shape of the support part of the module block may allow nesting or mechanical connection to another neighboring or peripheral module block according to the installation configurations chosen.

4. Design according to any one of the preceding claims, for which the shape of the support part of the module block may provide shapes to facilitate the flow and passage of rainwater.

5. Design according to any one of the preceding claims, for which the shape of the support part of the module block may provide

6. air passages or ventilation tunnels under the photovoltaic laminate to allow natural ventilation and thus reduce its heating. Design according to any one of the preceding claims, for which the shape of the support part of the module block may provide passageways and fixing channels for the electrical cables.

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