BIPV Module Edge Sealing via Extended Adhesive Layers
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Solution Overview
Problem
Building-integrated photovoltaic (BIPV) modules are susceptible to water incursion at the edge portions of their multi-layer top and back sheets, particularly near vapor barriers, which compromises their mechanical and electrical stability and longevity.
Innovation Solution
The modules are designed with multiple layers configured to be joined together during lamination to protect the edge portions of the top and back sheets, including the use of adhesive layers and encapsulant materials that extend beyond the vapor barrier structure to prevent water ingress, ensuring enhanced durability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If BIPV modules use multi-layer top and back sheets with vapor barriers, then water resistance is improved, but edge portions remain susceptible to water incursion compromising mechanical and electrical stability
Solution Approach 1:
The patent applies preliminary action by extending adhesive layers and encapsulant materials beyond the vapor barrier edges before water incursion can occur. This pre-positioned protective configuration ensures that edge portions are sealed and protected in advance, preventing water from penetrating between layers and compromising the module's stability.
Solution Approach 2:
The patent segments the protective structure into distinct functional zones: vapor barriers for bulk water resistance, extended adhesive layers for edge sealing, and encapsulant materials for additional protection. This segmentation allows each component to address specific vulnerability points, particularly at the edges where multiple layers meet.
2Reliability
If BIPV modules extend adhesive layers and encapsulant materials beyond vapor barrier edges, then edge protection is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the functions of adhesive layers and encapsulant materials into a unified extended protective configuration that covers both the vapor barrier edges and adjacent edge portions. This combination simplifies the manufacturing process by reducing the number of separate sealing operations needed while maintaining comprehensive edge protection.
Solution Approach 2:
The extended adhesive layers and encapsulant materials serve multiple functions simultaneously: they seal edge portions, prevent water incursion, provide mechanical bonding, and protect vapor barrier edges. This multi-functionality reduces the need for additional specialized components and simplifies the overall manufacturing process.
Data Source
AI summary
Improved BIPV materials configured to meet various long-term requirements including, among others, a high degree of water resistance, physical durability, electrical durability, and an ability to withstand variations in temperature and other environmental conditions. In some embodiments, the disclosed BIPV materials include modules wherein two or more layers of the module are configured to be joined together during lamination to protect edge portions of the top sheet and/or back sheet of the module, such as in the vicinity of any multi-layer vapor barrier structure(s) of the module.