Flexible Substrate Photovoltaic Module for Frameless Facade Integration
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Solution Overview
Problem
Existing solutions for integrating photovoltaic components into building facades are limited by high costs, constrained aesthetic options, and inefficiencies in electrical production and thermal comfort, while also requiring frames that can restrict design flexibility and increase production complexity.
Innovation Solution
A photovoltaic module design featuring separate sub-modules connected by a flexible substrate that can deform without affecting the sub-modules, allowing for movement and electrical connection without a frame, and a simplified manufacturing process involving a single lamination step to reduce costs and enhance modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid photovoltaic modules are fixed to the facade by means of a load-bearing mechanical structure, then structural stability is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a flexible substrate that can deform without affecting the photovoltaic sub-modules, replacing rigid mechanical support structures. This flexible substrate allows the module to adapt to facade movements while maintaining structural integrity, thereby reducing device complexity and cost without compromising stability.
Solution Approach 2:
The photovoltaic module is divided into separate sub-modules that are independently encapsulated. This segmentation allows each sub-module to be handled and supported independently, reducing the need for complex overall support structures while maintaining the stability of the entire assembly.
2Strength
If frames are used to reinforce rigidity and allow attachment, then structural strength is improved, but aesthetic flexibility and design options worsen
Solution Approach 1:
The flexible substrate serves as both the structural support and the encapsulation layer, eliminating the need for visible frames. This thin film approach maintains structural strength while providing a clean, frameless aesthetic that enhances design flexibility and visual appeal of the facade.
Solution Approach 2:
The flexible substrate performs multiple functions simultaneously: it provides structural support, encapsulates the photovoltaic cells for protection, and serves as the attachment interface. This multi-functionality eliminates the need for separate frames while maintaining both strength and aesthetic flexibility.
3Reliability
If multiple separate components are used for mounting and electrical connection, then functional reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines mechanical support and electrical connection functions into a single integrated flexible substrate. This merging of functions reduces the number of separate components needed, simplifying manufacturing processes and reducing costs while maintaining functional reliability through the unified design.
Solution Approach 2:
The flexible substrate is designed to perform multiple functions including mechanical support, electrical connection, and encapsulation. This multi-functional approach reduces component count and manufacturing complexity while ensuring reliable performance of all critical functions through a single integrated component.
4Manufacturing precision
If traditional multi-step manufacturing processes are used, then manufacturing precision is improved, but productivity and cost worsen
Solution Approach 1:
The patent combines multiple manufacturing steps into a single lamination process that simultaneously encapsulates the photovoltaic cells and forms the flexible substrate structure. This merging of operations maintains manufacturing precision through controlled lamination while significantly improving productivity by reducing process time and steps.
Solution Approach 2:
The flexible substrate is pre-formed with the necessary structural and electrical features before final assembly. This preliminary preparation allows for simpler, faster final assembly steps while maintaining precision through pre-positioned elements, thereby improving overall manufacturing efficiency without sacrificing quality.
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 design enhances electrical production, thermal comfort, and aesthetic flexibility while reducing costs and production complexity, allowing for a more efficient and visually appealing integration of photovoltaic components into building facades.
Implementation Method 1
a flexible substrate which can deform without affecting the sub-modules, allowing for movement
Implementation Method 2
a plurality of photovoltaic cells encapsulated in the substrate
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
The invention relates firstly to a photovoltaic module 1 comprising: - a substrate 11, and - a plurality of photovoltaic cells 12 encapsulated in the substrate, the module having: - a first part comprising the photovoltaic cells distributed into at least two photovoltaic sub-modules 2A, 2B, etc. disjoint from each other, and - a second part free of photovoltaic cells and extending from the first part of the module to form a linking member 3 joining the photovoltaic sub-modules together, the linking member, at least partly formed by the substrate 11, being configured to be mounted on a supporting structure 4 and to exhibit such flexibility that a deformation of the linking member 3 induces a movement of at least one, preferably several, potentially of each, of the photovoltaic sub-modules 2A, 2B, etc., without deforming them, said movement being a function of the deformation of the linking member.