Flexible Semi-Finished Photovoltaic Module for 3D Curved Surfaces

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Solution Overview

Problem

Existing photovoltaic solar panels are limited in customization and flexibility due to their rigid structure and standard sizes, which restricts their ability to be formed into custom 3D geometries, especially for non-planar installations like roofs and maritime applications.

Innovation Solution

A method for manufacturing a semi-finished photovoltaic module using flexible photovoltaic elements with back contactable terminals, where the laterally protruding side-portions are folded to form a back contactable terminal, allowing electrical connection from one side, and encapsulated with conductive wiring elements to simplify assembly and reduce complexity, enabling the formation of 3D solar panels with curvature along multiple axes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If rigid photovoltaic cells in standardized sizes are used, then manufacturing and assembly are simplified, but customization of size and 3D geometry is limited

Engineering Contradiction:

Improvemanufacturing and assembly simplicityVSAvoidcustomization of size and 3D geometry

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The photovoltaic panel is divided into multiple flexible photovoltaic elements that can be independently sized and shaped. Each element can be customized in dimensions and geometry while maintaining standardized manufacturing processes for individual components, thus resolving the contradiction between manufacturing simplicity and customization capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs flexible photovoltaic elements with thin-film construction that can be bent and formed into various 3D geometries. This flexibility allows customization of panel shapes for non-planar surfaces while maintaining ease of manufacture through standardized flexible element production and assembly processes.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If thin film PV cells with shingle-type arrangement are used, then flexibility along one axis is achieved, but 3D formability and dimensional customization remain limited

Engineering Contradiction:

Improveflexibility along one axisVSAvoiddimensional and formability limitations

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent transitions from 2D flexibility (shingle-type arrangement bending along one axis) to 3D formability by allowing photovoltaic elements to be bent and formed in multiple directions. The elements can be shaped into complex three-dimensional geometries, enabling installation on surfaces with curvature along multiple axes rather than being limited to single-axis bending.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If flexible photovoltaic elements with front and back electrodes are used, then electrical interconnection is achieved, but manufacturing complexity increases due to positioning requirements

Engineering Contradiction:

Improveelectrical interconnectionVSAvoidpositioning accuracy requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent inverts the traditional electrode arrangement by making both the front and back electrodes of adjacent photovoltaic elements contactable from the same side. This allows electrical interconnection to be achieved without complex positioning requirements, as all connections can be made from one side rather than requiring precise alignment between front and back surfaces of multiple elements.

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach allows for the creation of flexible, fully back contactable photovoltaic elements that can be easily interconnected and encapsulated, reducing manufacturing complexity and enabling the production of 3D solar panels that can be bent or curved without losing functionality, thus overcoming the limitations of traditional rigid panels.

Implementation Method 1

each flexible photovoltaic element (10) adapted to provide electric power when illuminated by a light irradiation on a light receiving front side

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS20230066735A1Flexible semi-finished photovoltaic module

Publication Date: 2023.03.02 NEDERLANDSE ORG VOOR TOEGEPAST NATUURWETENSCHAPPELIJK ONDERZOEK TNO

AI summary

The present disclosure relates to a 3D formable photovoltaic solar panel, in particular to a semi-finished free-formable photovoltaic module for a 3D formed solar panel, and to a method for manufacturing thereof. The semi-finished free-formable photovoltaic module comprising: a plurality of laterally spaced back contactable flexible photovoltaic elements; a plurality of flexible electrically conductive wiring elements forming an electrically conductive interconnection between flexible photovoltaic elements, each wiring element having an overlap with the respective back terminals of adjacent flexible photovoltaic elements; and an encapsulant over layer, wherein the encapsulant cover layer essentially fixates the overlaps of the wiring elements with respect to the respective back terminals.