A building integrated photovoltaic assembly

Abstract

This document describes a building integrated photovoltaic assembly that comprises a plurality of photovoltaic modules that are disposed on a housing of the photovoltaic assembly in a matrix configuration. The housing further includes an electrical interconnection network and a plurality of bypass diode mounting locations associated with the housing. The bypass diode mounting locations are configured to selectively receive and connect bypass diodes to the electrical interconnection network to adjust a density of bypass diodes across the photovoltaic modules, thereby mitigating performance losses due to shading or electrical mismatch.

Description

A BUILDING INTEGRATED PHOTOVOLTAIC ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to Singapore patent application no.10202500801T which was filed on 26 March 2025, the contents of which are hereby incorporated by reference in its entirety for all purposes.TECHNICAL FIELD

[0002] This application relates to a building integrated photovoltaic assembly that comprises a plurality of photovoltaic modules that are disposed on a housing of the photovoltaic assembly in a matrix configuration. The housing further includes an electrical interconnection network and a plurality of bypass diode mounting locations associated with the housing. The bypass diode mounting locations are configured to selectively receive and connect bypass diodes to the electrical interconnection network to adjust a density of bypass diodes across the photovoltaic modules, thereby mitigating performance losses due to shading or electrical mismatch.BACKGROUND

[0003] Although solar energy has become increasingly cost competitive with fossil fuelbased power generation, adoption of solar energy in many residential and commercial applications remains relatively limited. One factor influencing adoption is the visual impact of conventional solar installations. Traditional systems are frequently mounted above existing roofing materials or facade surfaces, causing the solar array to appear as a distinct and visually prominent structure. This separation between the photovoltaic modules and the underlying architectural elements can reduce the aesthetic appeal of the installation, particularly when viewed from street level or at a distance.

[0004] Those skilled in the art are increasingly using building integrated photovoltaic (BIPV) systems to generate electrical power while simultaneously serving as architectural elements of a building. However, the design of BIPV installations often involves a trade-off between cost and aesthetic value. Conventional photovoltaic panels are typically manufactured as standard, off-the-shelf modules that are relatively economical but visually uniform and plain. While such modules are suitable for many rooftop installations, they often provide limited flexibility when integrated into building facades or other architectural surfaces where aesthetic considerations are important. As a result, projects that require visually distinctive solar installations frequently rely on customized photovoltaic panels incorporatingcolors, patterns, or unique shapes, which can significantly increase manufacturing and installation costs.

[0005] As an example, when a large logo or decorative image is applied to a building facade using conventional photovoltaic panels, the design is typically divided into a grid corresponding to the dimensions of the available panels, which may be approximately 2 m2. As such, each panel may have to be custom printed to reproduce a specific portion of the image. Additionally, LED screens, conventional tiles, or agrivoltaics may also be used to form portions of the image. Such customized panels can be expensive to manufacture, and in some cases the cost may exceed several hundred dollars per square meter. In addition to the increased cost, printed or patterned panels may introduce uneven shading across the photovoltaic cells, resulting in electrical mismatch and reduced energy output. Furthermore, conventional photovoltaic modules typically incorporate a fixed and limited number of bypass diodes, such as one diode per group of approximately twenty cells, which may be insufficient to mitigate the effects of such localized shading.

[0006] In addition, the fixed dimensions of conventional photovoltaic panels often do not align well with the geometry of building facades or other architectural surfaces. As a result, installation layouts may include awkward gaps or unused areas where panels cannot be conveniently placed. These constraints can limit the ability of architects and designers to integrate photovoltaic systems seamlessly into building envelopes while maintaining the intended visual design.

[0007] As such, those skilled in the art are constantly looking for improved building integrated photovoltaic systems that allow greater design flexibility for architectural applications while mitigating electrical mismatch and shading effects and reducing the need for costly customized photovoltaic panels. Additionally, the improved building integrated photovoltaic systems should also be sufficiently flexible that they may be easily attached or plugged into existing systems.SUMMARY

[0008] In one aspect, the present disclosure describes a building integrated photovoltaic assembly comprising a housing having a plurality of mounting positions arranged in a matrix configuration and a plurality of photovoltaic (PV) modules disposed on the mounting positions of the housing such that the PV modules form a PV panel assembly. In embodiments of the disclosure, at least one of the PV modules comprises one or more active PV cells configuredto generate electrical power and / or at least one of the PV modules comprises a non-active module configured to visually mimic PV modules. The assembly also has an electrical interconnection network supported by the housing and electrically connecting the PV modules to form a PV array, and a plurality of bypass diode mounting locations associated with the housing and electrically coupled to the electrical interconnection network. In embodiments of the disclosure, each bypass diode mounting location is configured to receive a bypass diode electrically connected across selected nodes of the electrical interconnection network, and the bypass diode mounting locations are configured to selectively connect bypass diodes to the electrical interconnection network such that a density of bypass diodes across the PV array is configurable.

[0009] In accordance with embodiments of the one aspect, the PV modules are electrically interconnected through the electrical interconnection network in series, in parallel, or in a combination of series and parallel connections.

[0010] In accordance with embodiments of the one aspect, the non-active modules comprise tiles having colors, textures, or patterns configured to form an image, signage or decorative facade design.

[0011] In accordance with embodiments of the one aspect, each PV module comprises a mini-module stack mounted within a casing configured to be received in one of the mounting positions of the housing.

[0012] In accordance with embodiments of the one aspect, the mini-module stack comprises one or more photovoltaic cells encapsulated within one or more encapsulant layers and at least one transparent or semi-transparent layer overlaying the encapsulated photovoltaic cells.

[0013] In accordance with embodiments of the one aspect, at least one of the PV modules comprises a plurality of photovoltaic cells electrically connected together to form the active PV cell of the PV module.

[0014] In accordance with embodiments of the one aspect, the plurality of photovoltaic cells are arranged in a symmetrical or repeating configuration such that current matching is maintained within the PV module.

[0015] In accordance with embodiments of the one aspect, the bypass diode mounting locations are positioned at node points of the electrical interconnection network between electrically connected PV modules.

[0016] In accordance with embodiments of the one aspect, the density of the bypass diodes comprises one bypass diode per PV module, one bypass diode per three PV modules or one bypass diode per six PV modules.

[0017] In accordance with embodiments of the one aspect, a building integrated photovoltaic system may comprise a plurality of building integrated photovoltaic assemblies designed according to the one aspect installed on a building facade, wherein the assemblies comprise different configurations of bypass diodes that are connected to the respective electrical interconnection networks by selectively tapping different node points such that each assembly has a different density of bypass diodes based on expected shading conditions of corresponding regions of the building facade.

[0018] According to another aspect of the disclosure, a method for forming a building integrated photovoltaic assembly is disclosed. The method comprises the steps of providing a housing having a plurality of mounting positions arranged in a matrix configuration and disposing a plurality of photovoltaic (PV) modules on the mounting positions of the housing such that the PV modules form a PV panel assembly. In this embodiment, at least one of the PV modules may comprise one or more active PV cells configured to generate electrical power and / or at least one of the PV modules may comprise a non-active module configured to visually mimic PV modules. The method then includes the steps of electrically connecting the PV modules using an electrical interconnection network supported by the housing to form a PV array, providing a plurality of bypass diode mounting locations at the housing, the bypass diode mounting locations being electrically coupled to the electrical interconnection network; and selectively connecting bypass diodes to selected nodes of the electrical interconnection network at the bypass diode mounting locations such that a density of bypass diodes across the PV array is configurable.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Various embodiments of the present disclosure are described below with reference to the following drawings:Figure 1 illustrates a building having an integrated photovoltaic assembly in accordance with embodiments of the disclosure;Figure 2 illustrates a front view of a housing and its associated photovoltaic modules of a building integrated photovoltaic assembly in accordance with embodiments of the disclosure; Figures 3a and 3b illustrate schematic diagrams of distinct wiring and bypass diode interconnection strategies within the same housing geometry of the building integrated photovoltaic assembly in accordance with embodiments of the disclosure;Figure 4 illustrates an exploded cross-sectional view of an active photovoltaic module in accordance with embodiments of the disclosure;Figure 5 illustrates an exploded cross-sectional view of a non-active photovoltaic module in accordance with embodiments of the disclosure;Figure 6 illustrates a front view of an exemplary photovoltaic module assembly comprising four PV cells arranged in a 2x2 configuration, each PV cell exhibiting two-axis symmetry in accordance with an embodiment of the disclosure;Figure 7 illustrates a front view of a photovoltaic module assembly comprise non-active photovoltaic modules in accordance with an embodiment of the disclosure;Figure 8a illustrates a front view of a photovoltaic module assembly comprising a housing having a 3x4 matrix of photovoltaic modules in accordance with an embodiment of the disclosure;Figure 8b illustrates a front view of a photovoltaic module assembly comprising a housing having a 3x1 matrix of photovoltaic modules in accordance with an embodiment of the disclosureFigure 9a illustrates three different shading conditions across a building facade wherein the shading conditions include a colored photovoltaic image, shade from a building and shade caused by foliage;Figure 9b illustrates a comparison of modeled power loss under the shading conditions described in Figure 9a for various shade mitigation strategies;Figure 10 illustrates a flowchart showing a process for forming a building integrated photovoltaic assembly in accordance with embodiments of the disclosure.DETAILED DESCRIPTION

[0020] The following detailed description is made with reference to the accompanying drawings, showing details and embodiments of the present disclosure for the purposes of illustration. Features that are described in the context of an embodiment may correspondingly be applicable to the same or similar features in the other embodiments, even if not explicitly described in these other embodiments. Additions and / or combinations and / or alternatives as described for a feature in the context of an embodiment may correspondingly be applicable to the same or similar feature in the other embodiments.

[0021] In the context of various embodiments, the articles “a”, “an” and “the” as used with regard to a feature or element include a reference to one or more of the features or elements.

[0022] In the context of various embodiments, the term “about” or “approximately” as applied to a numeric value encompasses the exact value and a reasonable variance as generally understood in the relevant technical field, e.g., within 10% of the specified value.

[0023] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0024] As used herein, “comprising” means including, but not limited to, whatever follows the word “comprising”. Thus, use of the term “comprising” indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present.

[0025] As used herein, “consisting of’ means including, and limited to, whatever follows the phrase “consisting of’. Thus, use of the phrase “consisting of’ indicates that the listed elements are required or mandatory, and that no other elements may be present.

[0026] In the context of various embodiments, the term “disposed on" relates to the placement or deposition of one material or layer onto the surface of another and may involve one or more types of deposition techniques.

[0027] In the context of various embodiments, the directional terms mentioned herein, such as “above” and “below” or “upper” and “lower” refer to directions as described with reference to the drawings. Therefore, the directional terms are only used for illustration and are not meant to limit the present disclosure.

[0028] It should be noted that although the terms first, second and third are used herein to describe various elements, these elements should not be limited by these terms as these terms are meant to only distinguish one element from another element. Thus, the first element described herein could be termed as a second element without departing from this disclosure.

[0029] Additionally, for the sake of brevity, extensive explanations of details describing well-known structures and systems often associated with photovoltaic systems, roofs, etc., are not described in detail herein. Specifically, certain modules and components associated with photovoltaic systems are well known to one skilled in the art hence, detailed descriptions of such modules and components will be omitted entirely.

[0030] For the purpose of distinguishing between structural elements of the building integrated photovoltaic assembly, the terms photovoltaic (PV) module, PV cell, PV pixel, and PV panel assembly refer to components of the system that include solar energy collecting elements. In contrast, the housing refers to a structural support element configured to receive and support the PV modules. The housing may be attached to an exterior portion of a building, including a roof, wall, or facade. In the context of the present disclosure, a PV cell may refer to a photovoltaic element configured to function as an individual tile within a PV module or pixel. A PV module or pixel may comprise one or more PV cells electrically interconnected together, and a plurality of PV modules may be arranged within the housing in a matrix configuration to form the PV panel assembly.

[0031] Figure 1 illustrates a building integrated photovoltaic assembly 100 installed on an exterior surface of a building in accordance with an embodiment of the disclosure. Building integrated photovoltaic assembly 100 comprises a plurality of PV modules 102 arranged across exterior surfaces of the building such that the PV modules collectively form a photovoltaic panel assembly integrated into the building envelope. As illustrated, PV modules 102 are arranged in a grid-like configuration to cover a substantial portion of the facade of the building while simultaneously providing electrical power generation and architectural functionality.

[0032] In some embodiments, PV modules 102 may be arranged in horizontal rows or courses across the building surface. Vertically adjacent rows of PV modules 102 may be laterally offset relative to one another so that seams between adjacent rows do not align continuously across the entire surface. Such an arrangement may improve structural integration with the building envelope and provide a more visually uniform architectural appearance.

[0033] PV modules 102 may comprise active modules comprising photovoltaic cells configured to generate electrical power. In addition, some modules may be configured as nonactive modules that visually resemble the active modules. These non-active modules may beused in areas where photovoltaic cells cannot be conveniently installed or where electrical components, wiring harnesses, or other structural features of the building integrated photovoltaic assembly are located. By matching the appearance of the active modules, the non-active modules contribute to a consistent aesthetic appearance of the building surface.

[0034] In embodiments of the disclosure, PV modules 102 may be provided in various shapes and sizes depending on architectural and installation requirements. For example, PV modules 102 may comprise rectangular or square shapes, although other geometries such as curved or irregular shapes may also be used in certain embodiments. The modular nature of PV modules 102 enables building integrated photovoltaic assembly 100 to be adapted to different building geometries while maintaining a visually integrated facade or roof surface.

[0035] Figure 2 illustrates housing 200 of building integrated photovoltaic assembly 100 whereby housing 200 is configured to receive a plurality of PV modules 102 in accordance with an embodiment of the disclosure. Housing 200 includes a supporting frame defining a plurality of mounting positions 202 arranged in a matrix configuration. Each mounting position 202 is configured to receive and support a corresponding PV module 102 such that a plurality of PV modules 102 may be arranged across the housing to form a photovoltaic panel assembly.

[0036] As shown, mounting positions 202 are arranged in rows and columns across the housing 200 to form a grid-like structure. Housing 200 may be constructed from structural members that define the boundaries of the mounting positions and provide mechanical support for PV modules 102. The housing may also support electrical interconnection network and components that enable PV modules 102 installed within the mounting positions to be electrically interconnected.

[0037] In embodiments of the disclosure, each PV module 102 may comprise one or more PV tiles or cells 206a-206d. In the embodiment shown, PV module 102 includes a plurality of PV cells or tiles positioned around a central supporting structure. PV cells 206a-206d may be electrically interconnected within the PV module so that the module functions as an electrical unit that can be connected to other PV modules within or along housing 200. In some embodiments, PV module 102 may include a plurality of tile / cell sections integrally formed as a multi-tile module, where the number of tile sections is an integer equal to two or more. The PV cells contained within the respective tile sections may be electrically interconnected through internal bussing so that the PV module operates as a single electrical unit having apositive terminal and a negative terminal. In this manner, the PV module may function similarly to a conventional photovoltaic module and may be electrically connected to other PV modules within housing 200 through a harness or electrical interconnection network using a two-wire connection.

[0038] PV module 102 may further include mounting or connection features 205a and 205b configured to engage with corresponding portions of housing 200 when the PV module is installed in one of mounting positions 202. One skilled in the art will recognize that each module may comprise any number of connection features as these connection features are dependent on the number of PV cells / tiles in the PV module. These mounting features may provide both mechanical fixation and electrical coupling between the PV module and the electrical interconnection network supported by the housing. In some embodiments, the PV modules may be removably mounted within the housing to facilitate installation, replacement, or maintenance.

[0039] During installation, PV modules 102 may be sequentially inserted into mounting positions 202 of housing 200 as illustrated by the directional arrow in Figure 2. Once installed, the PV modules collectively form a photovoltaic panel assembly supported by the housing. The modular configuration of the PV modules and mounting positions enables the photovoltaic assembly to be constructed in different sizes and configurations depending on the architectural design requirements of the building surface on which the assembly is installed.

[0040] Figure 3a illustrates an exemplary electrical architecture of the building integrated photovoltaic assembly in accordance with an embodiment of the disclosure. As shown, a plurality of PV modules 102 are supported within housing 200 and electrically interconnected through an electrical interconnection network to form a photovoltaic array. PV modules 102 may be arranged in rows and columns corresponding to the mounting positions of the housing so that the PV modules collectively form a photovoltaic panel assembly integrated within the housing structure.

[0041] Housing 200 may further include a plurality of bypass diode mounting locations (not shown) associated with housing 200 and electrically coupled to the electrical interconnection network of the PV modules 102. Each bypass diode mounting location may be configured to receive a corresponding bypass diode 302 such that the bypass diode is electrically connected across selected nodes of the electrical interconnection network. The mounting locations may correspond to node points of the electrical interconnection network defined between variousPV modules 102 so that bypass diodes 302 can be electrically connected across selected portions of the photovoltaic array.

[0042] The bypass diode mounting locations may be supported by housing 200 such that bypass diodes 302 may be installed, replaced, or selectively positioned without requiring modification of individual PV modules 102. During operation, bypass diodes 302 provide a current bypass path when one or more PV modules 102 experience shading, electrical mismatch, or other conditions that reduce current generation. In such situations, a shaded or partially shaded PV module may become reverse biased due to current generated by other PV modules connected in series. When this occurs, the corresponding bypass diode may become forward biased, allowing electrical current to flow around the affected PV module rather than through it. This bypass path reduces the reverse voltage applied to the shaded PV module and mitigates power losses that would otherwise occur due to current mismatch.

[0043] By locating the bypass diode mounting locations within the housing rather than within the PV modules themselves, the electrical architecture of the photovoltaic assembly may be adjusted after installation ordering system design. In other words, unlike conventional photovoltaic panels in which bypass diodes are integrated within a module junction box and connected across fixed groups of photovoltaic cells, the present disclosure provides bypass diode mounting locations that are distributed along the electrical interconnection network supported by housing 200. This architecture allows the number and placement of bypass diodes to be selectively configured based on the arrangement of PV modules 102 and expected shading conditions of the installation site. In embodiments of the disclosure, bypass diodes may also be additionally integrated within each of PV modules 102 and this is left as a design choice to one skilled in the art.

[0044] For example, a bypass diode may be connected across a single PV module, across a group of PV modules, or across an entire row or column of PV modules. As illustrated in the non-limiting embodiment shown in Figure 3a, one bypass diode is connected across a group of three PV modules that are arranged in a series configuration, while Figure 3b illustrates another non-limiting embodiment whereby one bypass diode is connected across a group of six PV modules that are arranged in a series configuration. In this manner, a housing containing PV modules that are installed in facade regions where higher or more frequent shading is expected may be configured with a greater density of bypass diodes, whereas such housings installed in regions with relatively low shading may employ a lower density of bypass diodes. Such configurability enables optimization of system cost and electrical performancewhile mitigating current mismatch that may arise when heterogeneous facade patterns, images, or module configurations are used.

[0045] It should be noted that PV modules 102 may be electrically interconnected in series through the electrical interconnection network supported by housing 200. In such configurations, the positive terminal of a first PV module may be electrically coupled to the negative terminal of an adjacent PV module so that the voltage generated by the individual PV modules is cumulatively increased along the series connection path. A plurality of PV modules arranged along a row or column of the housing may therefore form a series-connected string of PV modules.

[0046] In other embodiments, groups of PV modules 102 or strings of series-connected PV modules may be electrically interconnected in parallel. In such a parallel configuration, the positive terminals of multiple PV modules or strings may be electrically coupled together while the corresponding negative terminals are also electrically coupled together. Such parallel interconnections may increase the total current output of the photovoltaic assembly while maintaining a substantially constant operating voltage.

[0047] In still other embodiments, the electrical interconnection network supported by housing 200 may include both series and parallel electrical connections. For example, a plurality of PV modules 102 may first be interconnected in series to form multiple series strings, and these series strings may then be electrically connected in parallel to produce a desired voltage and current output for the building integrated photovoltaic assembly. The specific electrical configuration may be selected based on the power requirements of the installation and the characteristics of associated power conversion equipment.

[0048] In embodiments of the disclosure, bypass diodes 302 may comprise semiconductor diodes suitable for photovoltaic bypass applications. Examples of suitable bypass diodes include, but are not limited to, Schottky diodes, silicon PN junction diodes, fast-recovery diodes, or other semiconductor diodes having relatively low forward voltage characteristics. Such diodes may be selected to handle the current produced by PV modules 102 while minimizing power dissipation when the bypass path is activated.

[0049] Figure 4 illustrates an exploded cross-sectional view of active PV module 400 in accordance with an embodiment of the disclosure. PV module 400 may comprise a minimodule stack mounted within module casing 402 or an embedded structure. In theembodiment with module casing 402, the mini-module stack may include one or more photovoltaic solar cells 405 encapsulated between encapsulant layers 404 and 406, with rear transparent layer 403 and front transparent layer 408 providing structural support and environmental protection. Transparent layers 403 and 408 may comprise any transparent material such as, but is not limited to, glass or plastic. Module casing 402 may provide mechanical support for the mini-module stack and may further include structural features for mounting the PV module within the housing described herein. In the embodiment which employs an embedded structure, the mechanical mounting points may be provided within transparent layers 403 and 408, and module casing 402 may be omitted from this embodiment as the mounting points on the transparent layers allow the mini-module stack to be directly mounted onto the housing as required. Additionally, mechanical mounting points and parts of the electrical interconnection network may be provided on these transparent layers instead of the housing. In embodiments of the disclosure, transparent layers 403 and / or 408 may also comprise semi-transparent layers.

[0050] The mini-module stack may be fabricated using conventional photovoltaic lamination processes. For example, photovoltaic solar cell 405 may be positioned between encapsulant layers 404 and 406 and laminated together with front glass 408 and rear glass 403 to form a sealed photovoltaic structure. The laminated structure may then be secured to module casing 402 so that PV module 400 functions as a modular photovoltaic tile that can be installed within a corresponding mounting position of the housing.

[0051] In some embodiments, PV module 400 may include aesthetic features configured to provide architectural design flexibility. For example, a coloured insert 407 may be disposed between front glass 408 and encapsulant layer 406 to introduce color or decorative patterns to the PV module. Other techniques for introducing color may also be used, including coloured encapsulants, printed glass layers, or light-emitting elements such as LEDs. These aesthetic features may enable PV modules to be arranged in patterns or images across a building fagade while maintaining photovoltaic functionality.

[0052] In embodiments where the PV module includes a plurality of photovoltaic solar cells 405, cells 405 may be arranged so that decorative patterns applied to the module exhibit symmetry about two axes. Such dual-axis symmetry may assist in maintaining electrical current matching between photovoltaic solar cells 405 even when coloured inserts or printed patterns are present on the module surface.

[0053] In such an embodiment, photovoltaic cells 405 may be electrically interconnected through internal wiring or bussing to form an electrically functional module. As a non-limiting example, PV module 400 may comprise four photovoltaic cells arranged in a 2x2 configuration within the mini-module stack. Electrical interconnections may be formed using conductive ribbons, busbars, or other conductive elements that electrically couple the cells together. Specifically, the photovoltaic cells may be connected in a series configuration such that a positive terminal of a first photovoltaic cell is electrically coupled to a negative terminal of an adjacent photovoltaic cell, thereby increasing the output voltage of the module. Alternatively, the cells may be connected in parallel or in a combination of series and parallel configurations depending on the desired electrical output characteristics. The internal wiring may route electrical current from the interconnected photovoltaic cells to module output terminals provided within PV module 400 so that electrical power generated by the photovoltaic cells can be supplied to the electrical interconnection network of the housing when PV module 400 is installed within the building integrated photovoltaic assembly.

[0054] For completeness, it is worth noting that PV module 400 may be compatible with a variety of photovoltaic solar cell technologies. For example, crystalline silicon cells, thin-film photovoltaic cells, or other semiconductor photovoltaic devices may be used. In some embodiments, back-contact photovoltaic cells may be used due to their relatively low breakdown voltages, which can improve shade tolerance when the PV modules are incorporated into the building integrated photovoltaic assembly described herein.

[0055] Figure 5 illustrates an example of a non-active PV module 500 in accordance with an embodiment of the disclosure. Non-active PV module 500 may comprise a structural tile that visually resembles an active PV module (such as active PV module 400) but does not contain photovoltaic solar cells. In the illustrated embodiment, non-active PV module 500 comprises non-PV cladding layer 502 mounted onto module casing 402. As mentioned in the previous sections, module casing 402 may be configured to mechanically engage with the housing of the building integrated photovoltaic assembly in a similar manner to the active PV modules described herein.

[0056] In contrast to active PV modules that include photovoltaic cells for generating electrical power, non-active PV module 500 may comprise a stack primarily formed from architectural cladding material. Cladding layer 502 may be secured to module casing 402 so that non-active PV module 500 can be installed within the same mounting positions of the housing as the active PV modules. As a result, the non-active PV modules may beinterchanged with active PV modules while maintaining a consistent mechanical interface with the housing.

[0057] Cladding layer 502 may be formed from a variety of architectural materials depending on the desired aesthetic appearance of the building fagade. Examples of suitable materials include wood, marble, stone, metal cladding, composite architectural panels, vegetation-based fagade elements, or other decorative building materials. These materials may be selected to create specific visual textures, colors, or patterns across the building surface.

[0058] By incorporating non-active PV modules alongside active PV modules within the same housing structure, designers may create heterogeneous fagade designs while preserving the overall appearance of a continuous photovoltaic installation. In certain embodiments, the non-active PV modules may be used in locations where photovoltaic power generation is not required or where architectural design considerations dictate the use of alternative surface materials.

[0059] In embodiments of the disclosure, a PV module may comprise a hybrid structure which includes both PV elements and architectural cladding elements within the same module. For example, the PV module may include one or more photovoltaic solar cells disposed within a first portion of the module and a non-photovoltaic cladding portion disposed within a second portion of the module. The cladding portion may comprise decorative or architectural materials such as printed glass, coloured inserts, wood, stone, metal cladding, composite panels, vegetation-based facade materials, or other architectural elements. In such embodiments, the photovoltaic solar cells are configured to generate electrical power while the cladding portion provides a desired visual appearance for the building fagade (i.e. , does not have a PV solar cell layer). The hybrid PV module may therefore enable the creation of heterogeneous facade designs while maintaining compatibility with the mounting positions and electrical interconnection network of the housing described herein.

[0060] Figure 6 illustrates a front view of an exemplary PV module comprising four PV cells 602a-602d arranged in a 2x2 configuration in accordance with an embodiment of the disclosure. Each PV module includes a decorative pattern formed from a plurality of PV tiles / cells. In the illustrated embodiment, the decorative pattern is configured with symmetry about two orthogonal axes so that the pattern is substantially identical when reflected across horizontal and vertical axes.

[0061] The arrangement of PV cells / tiles that produces a decorative pattern exhibiting two-axis symmetry may assist in maintaining electrical current matching among the PV cells contained within the PV modules. When decorative patterns, coloured inserts, or printed elements are applied to PV modules, variations in light transmission may occur across the module surface. By arranging the pattern with two-axis symmetry, any shading or optical attenuation introduced by the pattern may be distributed uniformly across the photovoltaic cells, thereby reducing the likelihood of current mismatch between cells within the PV module. This arrangement enables the incorporation of decorative or architectural patterns while maintaining stable electrical performance of the photovoltaic assembly.

[0062] Figure 7 illustrates some exemplary surface appearances 702a-702c that may be used in the building integrated photovoltaic assembly in accordance with an embodiment of the disclosure. In the illustrated embodiment, the PV modules, which may be active or nonactive modules, may include decorative or architectural surface patterns configured to resemble natural or construction materials. For example, surface 702a may include a surface pattern resembling wood grain, surface 702b may include a surface pattern resembling marble or stone, and surface 702c may include a surface pattern resembling textured or vegetative materials. Such decorative patterns may be incorporated into the PV modules using techniques such as printed glass, coloured inserts, coloured encapsulants, or other surface treatment processes. In some embodiments, the patterns may be arranged with symmetry about two axes or in repeating patterns so that light transmission across the PV module surface remains substantially uniform.

[0063] Figure 8a illustrates a mock-up of a housing supporting a plurality of PV modules arranged in a matrix configuration in accordance with an embodiment of the disclosure. In the illustrated example, the housing comprises a 3x4 arrangement of mounting positions populated with PV modules configured as patterned tiles. The PV modules may be installed within the housing so that the modules collectively form a photovoltaic panel assembly while simultaneously providing a decorative facade surface. The housing described herein may be manufactured in a variety of sizes depending on installation requirements. For example, while Figure 8a illustrates a housing having a 3x4 module configuration, larger housings may also be fabricated. In some embodiments, housings having configurations such as 5x10 modules may be used to approximate the dimensions of conventional photovoltaic panels. Housings of different sizes may be used in combination so that the photovoltaic assemblies can moreefficiently utilize available building facade areas and accommodate architectural features such as windows, edges, or irregular wall dimensions.

[0064] Figure 8b illustrates a prototype housing having a 3x1 module configuration that was fabricated to demonstrate feasibility of the modular housing concept. The prototype includes PV modules arranged vertically within a narrow housing structure. Initial testing of the prototype demonstrated reliable mechanical mating between the PV modules and the housing.

[0065] Figure 9a illustrates a comparison between conventional PV panel systems and building integrated photovoltaic assemblies designed in accordance with embodiments of the disclosure. The conventional PV panel system and the building integrated photovoltaic assembly each have approximate dimensions of 12 meters by 5 meters. In Figure 9a, conventional PV panels 901 are represented using dashed outlines while the building integrated photovoltaic assembly comprise a plurality of PV modules 903 that are illustrated as a fine grid of PV modules 903 arranged in a 5 x 6 matrix configuration.

[0066] Preliminary modelling is then performed on the conventional PV panel systems and the building photovoltaic assemblies illustrated in Figure 9a under three different shading scenarios. Specifically, a first scenario 902 represents a light shading scenario caused by decorative photovoltaic imagery or coloured surface patterns, such as coloured PV images having opacity levels between approximately 20% and 35%. A second scenario 904 represents a heavy shading scenario caused by shadows cast by adjacent buildings or other large structures, resulting in shading levels of approximately 60% to 70% opacity across portions of the facade. A third scenario 906 represents a spread or distributed shading scenario caused by irregular shadow patterns such as those produced by foliage, which may produce shading variations ranging from approximately 0% to 70% opacity across the surface of the PV array.

[0067] Hence, to evaluate the electrical performance under these three shading conditions, simulations were conducted on building photovoltaic assemblies constructed using the cellbased photovoltaic modules described herein and on a similarly sized system constructed using conventional PV panels. In the modelled configurations, the PV cells / tiles and the subsequent PV modules of the proposed system were electrically connected in series and coupled to a string inverter configured to track and select a maximal global power output from the photovoltaic array.

[0068] For comparison, the system that employed conventional PV panels included individual PV panels that were equipped with power optimizers, which are commonly used to mitigate the effects of shading on photovoltaic systems. In addition, the building photovoltaic assemblies constructed using the PV modules described herein were simulated using two types of bypass diodes, conventional bypass diodes having activation voltages of approximately 320 millivolts and low-activation or “smart” bypass diodes having activation voltages of approximately 75 millivolts. The modelling results obtained from these simulations are further illustrated in Figure 9b.

[0069] Figure 9b illustrates the simulated power loss results for the shading scenarios described in Figure 9a. The bar graphs compare the electrical performance of: (1) the proposed building photovoltaic assembly when conventional bypass diodes were used - 910; (2) the proposed building photovoltaic assembly when smart bypass diodes were used - 912; and (3) a PV system that utilized conventional PV panels equipped with power optimizers -914.

[0070] The simulation results show that when conventional bypass diodes were used with the proposed building PV assembly (configuration 910), this configuration produced the highest power loss across all three shading conditions, with total power loss (Pioss) ranging from approximately 26% to 39%. This performance degradation may be attributed to relatively large reverse voltages that develop across the shaded PV modules of the assembly before the conventional bypass diodes become forward biased. The resulting voltage drop then leads to power dissipation and reduced overall system efficiency when shading conditions are present.

[0071] In the configuration where smart bypass diodes were used, i.e. configuration 912, it was found that the smart bypass diodes activate at lower forward voltages, thereby allowing current to bypass shaded modules more quickly. Under the same shading scenarios, this configuration 912 demonstrated reduced power loss values ranging from approximately 21% to 27%. These results indicate that low activation voltage bypass diodes can significantly improve the shading tolerance of the integrated building PV assembly described herein.

[0072] Furthermore, based on the results shown in Figure 9b, it can be seen that the performance of the smart bypass diode configuration 912 was found to be comparable to that of photovoltaic systems that employ conventional PV panels with power optimizers, i.e.configuration 914, which exhibited power loss values between approximately 23% and 27% across the modelled shading conditions. While power optimizers and other module-level electronics may improve shading performance, such components often require replacement after approximately 10 to 15 years of field operation. In contrast, bypass diodes are generally rated to operate for the full-service lifetime of photovoltaic modules, which may extend to approximately 25 to 30 years.

[0073] These preliminary modelling results demonstrate that the proposed building PV assembly described herein can provide competitive shading mitigation performance while relying on relatively simple and durable bypass diode technology. In addition, the configurable placement and density of bypass diodes within the housing architecture may enable further optimization of shading tolerance across different facade regions of a building installation.

[0074] A process for forming a building integrated photovoltaic assembly in accordance with embodiments of the disclosure is illustrated in Figure 10. Process 1000 begins at step 1002 with process 1000 providing a housing having a plurality of mounting positions arranged in a matrix configuration. At step 1004, process 1000 then disposes a plurality of PV modules on the mounting positions of the housing such that the PV modules form a PV panel assembly. In embodiments of the disclosure, at least one of the PV modules comprises one or more active PV cells configured to generate electrical power and / or at least one of the PV modules comprises a non-active module configured to visually mimic PV modules. Process 1000 then electrically connects the PV modules using an electrical interconnection network supported by the housing to form a PV array. This takes place at step 1006. At step 1008, process 1000 then provides a plurality of bypass diode mounting locations at the housing where each of the bypass diode mounting locations are electrically coupled to the electrical interconnection network. Process 100 then selectively connects bypass diodes to selected nodes of the electrical interconnection network at the bypass diode mounting locations such that a density of bypass diodes across the PV array is configurable. This takes place at step 1010.

[0075] In embodiments of the disclosure, process 1000 may electrically interconnect the PV modules through the electrical interconnection network in series, in parallel, or in a combination of series and parallel connections. Further, the non-active modules may comprise tiles having colors, textures, or patterns configured to form an image or decorative facade design. Additionally, each PV module may comprise a mini-module stack mounted within a casing configured to be received in one of the mounting positions of the housing and the mini-module stack may comprise one or more photovoltaic cells encapsulated within one or more encapsulant layers and at least one glass layer overlaying the encapsulated photovoltaic cells.

[0076] In embodiments of the disclosure, process 1000 may arrange the plurality of photovoltaic cells in a symmetrical configuration such that current matching is maintained within the PV module.

[0077] In embodiments of the disclosure, the bypass diodes may be integrated into the housing frame before the PV modules are attached to their respective mounting positions on the housing. These bypass diodes would be static and non-adjustable but would make for less complex assembly. As a non-limiting example, there could be different types of frames, for example: low, medium and high BPD density frames, each compatible with one another and this would be left as a design choice to one skilled in the art.

[0078] Numerous other changes, substitutions, variations, and modifications may be ascertained by the skilled in the art and it is intended that the present application encompass all such changes, substitutions, variations and modifications as falling within the scope of the appended claims.

Claims

CLAIMS:

1. A building integrated photovoltaic assembly comprising:a housing having a plurality of mounting positions arranged in a matrix configuration; a plurality of photovoltaic (PV) modules disposed on the mounting positions of the housing such that the PV modules form a PV panel assembly,wherein at least one of the PV modules comprises one or more active PV cells configured to generate electrical power;an electrical interconnection network supported by the housing and electrically connecting the PV modules to form a PV array;a plurality of bypass diode mounting locations associated with the housing and electrically coupled to the electrical interconnection network,wherein each bypass diode mounting location is configured to receive a bypass diode electrically connected across selected nodes of the electrical interconnection network, andwherein the bypass diode mounting locations are configured to selectively connect bypass diodes to the electrical interconnection network such that a density of bypass diodes across the PV array is configurable.

2. The building integrated photovoltaic assembly according to claim 1, wherein at least one of the PV modules comprises a non-active module configured to visually mimic the PV modules.

3. The building integrated photovoltaic assembly according to claim 1, wherein the PV modules are electrically interconnected through the electrical interconnection network in series, in parallel, or in a combination of series and parallel connections.

4. The building integrated photovoltaic assembly according to claim 2 wherein the non-active modules comprise tiles having colors, textures, or patterns configured to form an image or decorative facade design.

5. The building integrated photovoltaic assembly according to any one of claims 1 or 2, wherein each PV module comprises a mini-module stack mounted within a casing or embedded connection points that are each configured to be received in one of the mounting positions of the housing.

6. The building integrated photovoltaic assembly according to claim 5, wherein the minimodule stack comprises one or more photovoltaic cells encapsulated within one or more encapsulant layers and at least one transparent layer overlaying the encapsulated photovoltaic cells.

7. The building integrated photovoltaic assembly according to claim 1, wherein at least one of the PV modules comprises a plurality of photovoltaic cells electrically connected together to form the active PV module.

8. The building integrated photovoltaic assembly according to claim 7, wherein the plurality of photovoltaic cells is arranged in a symmetrical or repeating configuration such that current matching is maintained within the PV module.

9. The building integrated photovoltaic assembly according to claim 1, wherein the bypass diode mounting locations are positioned at node points of the electrical interconnection network between electrically connected PV modules.

10. A building integrated photovoltaic system comprising:a plurality of building integrated photovoltaic assemblies according to claim 1 installed on a building facade, wherein the assemblies comprise different configurations of bypass diodes that are connected to the respective electrical interconnection networks by selectively tapping different node points such that each assembly has a different density of bypass diodes based on expected shading conditions of corresponding regions of the building facade.

11. A method of forming a building integrated photovoltaic assembly comprising:providing a housing having a plurality of mounting positions arranged in a matrix configuration;disposing a plurality of photovoltaic (PV) modules on the mounting positions of the housing such that the PV modules form a PV panel assembly,wherein at least one of the PV modules comprises one or more active PV cells configured to generate electrical power;electrically connecting the PV modules using an electrical interconnection network supported by the housing to form a PV array;providing a plurality of bypass diode mounting locations at the housing, the bypass diode mounting locations being electrically coupled to the electrical interconnection network; andselectively connecting bypass diodes to selected nodes of the electrical interconnection network at the bypass diode mounting locations such that a density of bypass diodes across the PV array is configurable.

12. The method according to claim 11 wherein at least one of the PV modules comprises a non-active module configured to visually mimic the PV modules.

13. The method according to claim 11, further comprising:electrically interconnecting the PV modules through the electrical interconnection network in series, in parallel, or in a combination of series and parallel connections.

14. The method according to claim 12 wherein the non-active modules comprise tiles having colors, textures, or patterns configured to form an image or decorative facade design.

15. The method according to any one of claims 11 or 12, wherein each PV module comprises a mini-module stack mounted within a casing or embedded connection points that are each configured to be received in one of the mounting positions of the housing.

16. The method according to claim 15, wherein the mini-module stack comprises one or more photovoltaic cells encapsulated within one or more encapsulant layers and at least one glass layer overlaying the encapsulated photovoltaic cells.

17. The method according to claim 11, wherein at least one of the PV modules comprises a plurality of photovoltaic cells electrically connected together to form the active PV module.

18. The method according to claim 17, wherein the plurality of photovoltaic cells is arranged in a symmetrical or repeating configuration such that current matching is maintained within the PV module.

19. The method according to claim 11, wherein the bypass diode mounting locations are positioned at node points of the electrical interconnection network between electrically connected PV modules.

20. The method according to claim 11, wherein the density of the bypass diodes comprises one bypass diode per PV module, one bypass diode per three PV modules or one bypass diode per six PV modules.

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