Cuttable Photovoltaic Modules for Irregular Building Surfaces
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Solution Overview
Problem
Existing photovoltaic systems face limitations in covering building envelope surfaces efficiently due to the fixed sizes of commercially available modules, which can leave areas uncovered and compromise the laminate structure and electrical wiring, leading to reduced service life and incomplete energy generation.
Innovation Solution
Photovoltaic modules can be flexibly cut to desired sizes on-site using compact cutting devices, such as tile and glass cutting machines or laser beams, with subsequent deburring and sealing to maintain structural integrity and prevent moisture ingress, allowing for complete coverage of irregularly shaped surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If photovoltaic modules are manufactured in fixed standard sizes, then mass production efficiency and cost-effectiveness are improved, but the ability to cover non-standard building envelope surfaces is worsened
Solution Approach 1:
The photovoltaic module is divided into multiple independent solar cell strings with individual bypass diodes. This segmentation allows the module to be partially cut and still maintain functionality of the remaining sections, enabling adaptation to non-standard building surfaces while preserving mass production benefits.
Solution Approach 2:
The module design incorporates bypass diodes that dynamically redirect current flow around defective or cut sections. This dynamic electrical reconfiguration allows the module to adapt its functional configuration based on physical modifications, enabling on-site cutting while maintaining system productivity.
2Adaptability or versatility
If photovoltaic modules are cut on-site to fit surfaces, then adaptability to building envelope surfaces is improved, but the risk of damaging the laminate structure and reducing service life is worsened
Solution Approach 1:
Bypass diodes are pre-installed on each solar cell string before module assembly. This preliminary action ensures that the electrical protection mechanism is already in place, allowing safe on-site cutting without compromising the integrity of the remaining functional sections.
Solution Approach 2:
The bypass diodes serve as a protective cushion against the harmful effects of partial cutting. By providing alternative current paths before cutting occurs, they prevent damage propagation and maintain module reliability even after physical modification.
3Stability of the object's composition
If photovoltaic modules are left in standard sizes without manipulation, then the laminate structure integrity is preserved, but complete coverage of building envelope surfaces cannot be achieved
Solution Approach 1:
The module design assigns different functional roles to different sections through the string-and-bypass-diode architecture. Each solar cell string with its bypass diode represents a locally optimized unit that can independently contribute to power generation, allowing selective retention of functional sections after cutting.
Solution Approach 2:
The bypass diode mechanism enables the system to effectively discard non-functional or cut sections while recovering and maintaining full operational capability of the remaining sections. This allows maximized utilization of the module area after on-site adaptation.
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
This method enables optimal utilization of building surfaces by allowing flexible adaptation of photovoltaic modules to fit unique shapes, maximizing energy generation while ensuring the integrity and longevity of the laminate structure and electrical connections.
Implementation Method 1
A photovoltaic module 1 to be cut to size with a front protective pane 120 made of unhardened glass is cut to size on the construction site using a cutting device by cutting off a section of the photovoltaic module 1 along at least one marking M
Implementation Method 2
The cutting can also be carried out by breaking scratched photovoltaic modules 1
Data Source
Figure 1~2d
Figure 3
AI summary
In a method for creating photovoltaic systems with a plurality of rigid photovoltaic modules (1) in a desired shape, which can be carried out directly on site at a construction site or workshop, the photovoltaic module (1) having an encapsulated laminate structure (12) comprising a front protective pane (120), a matrix material ( 121) which encloses a front electrode layer (122) and a photovoltaic layer (123) and has a rear electrode layer (124) and a rear wall (125), with electrical connections (10) on one side of the photovoltaic module (1), an optimized photovoltaic use of the building shell should be achieved. This is done by cutting at least one of the photovoltaic modules (1) to match at least one marking (M) that defines a detachable cutting area (S) on the photovoltaic module (1), the cutting being performed at a lateral distance from the electrical connections (11).