Frameless PV Module Design for Architectural Integration
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Solution Overview
Problem
The solar industry faces challenges in reducing system costs due to high material and manufacturing costs, low solar module efficiency, and the need for refined silicon, which limits the scale of solar power development compared to coal and liquid fossil fuels. Current photovoltaic panels require structural frames and grounding elements, increasing costs and complicating integration into architectural applications.
Innovation Solution
A frameless photovoltaic module design using optically transparent substrates, such as glass, without a structural frame or electrically-conducting grounding element, where PV cells are sandwiched between laminated substrates, and optionally include diffractive optical components, to reduce costs and enhance integration into architectural features like windows and skylights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a structural frame is added to the PV module to improve mechanical strength and rigidity, then the structural integrity is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The patent removes the structural frame from the PV module design, extracting the framing component entirely. The module consists only of PV cells mounted on a backsheet with a junction box, eliminating the need for complex frame structures while maintaining functional integrity through simplified mounting systems.
Solution Approach 2:
The patent employs a flexible backsheet as the primary structural component instead of rigid frames. This thin film provides the necessary support and protection while allowing for easier installation and integration into various surfaces, reducing both complexity and cost.
2Ease of operation
If a structural frame is added to the PV module to facilitate mechanical attachment, then the ease of installation is improved, but the manufacturing cost increases
Solution Approach 1:
The patent eliminates the structural frame component, reducing the number of parts that need to be manufactured and assembled. This simplification directly reduces manufacturing costs while the integrated backsheet design provides adequate support for mechanical attachment.
Solution Approach 2:
The patent combines the structural support function and the protective backing function into a single integrated backsheet component. This merging of functions reduces the total number of components, simplifies manufacturing, and lowers overall costs while maintaining installation capability.
3Reliability
If an electrically-conducting grounding element is added to the PV module to improve electrical safety, then the reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent makes the aluminum junction box serve multiple functions: it provides electrical connection, housing for electrical components, and simultaneously acts as the grounding element. This multi-functionality eliminates the need for separate grounding components, reducing complexity while maintaining electrical safety.
Solution Approach 2:
The patent combines the electrical connection function and the grounding function into a single aluminum junction box component. This integration reduces the total number of parts and simplifies the module structure while ensuring electrical safety through the conductive properties of the aluminum housing.
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
The frameless design reduces module and installation costs, enhances structural integrity, and facilitates easier integration into architectural applications while maintaining or improving solar energy conversion efficiency, particularly with bifacial PV cells, and provides increased protection and rigidity without external frames.
Implementation Method 1
photovoltaic (PV) conversion of solar radiation
Data Source
AI summary
A photovoltaic module employing an array of photovoltaic cells disposed between two optically transparent substrates such as to define a closed-loop peripheral area of the module that does not contain a photovoltaic cell. The module is sealed with a peripheral seal along the perimeter; and is devoid of a structural element affixed to an optically transparent substrate and adapted to mount the module to a supporting structure. The two substrates may be bonded together with adhesive material and, optionally, the peripheral seal can include the adhesive material. The module optionally includes diffraction grating element(s) adjoining respectively corresponding PV-cell(s).