Angled Polymer Solar Modules for Enhanced Energy Harvest
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Solution Overview
Problem
Conventional solar modules with rigid structural frames and glass encapsulation often result in poor energy harvest due to a flat orientation, which can be improved by using angled polymer solar modules that receive more sunlight, thereby increasing energy production and reducing installation time and costs.
Innovation Solution
The development of angled polymer solar modules that are lightweight, flexible, and lack a rigid structural frame or glass encapsulation, allowing them to be installed on rooftops with low load requirements, and featuring a design that maximizes sunlight exposure by angling the PV cells to face the sun, potentially eliminating the need for racking systems and improving cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solar modules with rigid structural frames and glass encapsulation are used, then structural strength is improved, but energy harvest deteriorates due to flat orientation
Solution Approach 1:
The patent replaces rigid structural frames and glass encapsulation with flexible polymer encapsulation layers. The PV cells are directly encapsulated in polymer without rigid framing, allowing the modules to be bent and angled for optimal sunlight exposure while maintaining structural integrity through the polymer encapsulation itself.
Solution Approach 2:
The patent enables dynamic orientation of PV cells by allowing them to be angled relative to the support surface. The flexible polymer construction permits the modules to be installed at various angles (e.g., 30-60 degrees) to maximize energy harvest, rather than being constrained to flat orientations.
2Productivity
If angled polymer solar modules are used, then energy harvest is improved, but structural stability deteriorates under wind and snow loads
Solution Approach 1:
The patent uses composite polymer encapsulation structures consisting of multiple polymer layers with different properties. These composite polymer structures provide both flexibility for angling and sufficient strength to withstand environmental loads when properly installed.
Solution Approach 2:
The patent combines the structural support function with the encapsulation function by using the polymer encapsulation layers to provide both protection and structural support. The PV cells, polymer encapsulation, and support surface work as an integrated system where the angled configuration itself contributes to structural stability.
3Strength
If rigid structural frames are used, then structural integrity is improved, but installation time and costs increase
Solution Approach 1:
The patent removes the separate rigid structural frame component entirely, extracting this function from the system. The polymer encapsulation directly provides structural support without requiring additional framing materials, simplifying the overall structure and reducing installation complexity.
Solution Approach 2:
The polymer encapsulation serves multiple functions simultaneously: it protects the PV cells from environmental damage, provides structural support, enables flexible angling, and eliminates the need for separate framing systems. This multi-functionality reduces both material requirements and installation time.
4Ease of operation
If polymer encapsulation without rigid frames is used, then installation ease is improved, but resistance to wind and snow deteriorates
Solution Approach 1:
The patent changes the physical parameters of the encapsulation material from rigid (glass and metal frames) to flexible polymer materials. This parameter change allows for easier installation and angling while the polymer's inherent properties and the angled configuration provide resistance to wind and snow loads.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These modules enhance energy harvest, reduce installation time and costs, and provide improved operating temperatures due to airflow, while maintaining structural integrity to withstand wind and snow, and can be easily transported and installed without breaking.
Implementation Method 1
Photovoltaic (PV) cells, commonly known as solar cells, are devices for converting solar radiation into electrical energy
Implementation Method 2
improving normal operating condition temperatures for the solar modules since air may flow above and below the modules
Data Source
AI summary
This specification describes angled polymer solar modules, methods for producing angled polymer solar modules, and methods for installing angled polymer solar modules. In some examples, a method includes producing a flat polymer sheet including one or more photovoltaic cells. The method includes applying force to the flat polymer sheet to curve the flat polymer sheet in at least one region, forming an angled polymer sheet from the flat polymer sheet. The method includes mounting the angled polymer sheet on a roof deck such that the photovoltaic cells are angled with respect to the roof deck by virtue of the at least one region being curved.