Inter-tile Spacer for Solar Roof Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic roof tile systems face challenges with mechanical support, inter-tile electrical connections, and weather protection, particularly in multi-tile modules, where the encapsulant-filled gaps are structurally weak and aesthetically unappealing, and exposed electrical connections are vulnerable to weather damage.
Innovation Solution
A reinforcement spacer with a base and wings is embedded between photovoltaic roof tiles, providing mechanical support, facilitating electrical connections, and directing encapsulant flow, while being made from UV-resistant and waterproof materials like PVDF or PTFE to enhance structural integrity and aesthetic appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photovoltaic roof tiles are joined with encapsulant-filled gaps, then the tiles are protected from weather elements, but the gaps create structurally weak and aesthetically unappealing joints
Solution Approach 1:
A spacer is introduced as an intermediary component between adjacent photovoltaic roof tiles. The spacer provides mechanical support and creates a defined joint structure that is both structurally sound and visually appealing, while the encapsulant fills the remaining space for weather protection without bearing structural loads
Solution Approach 2:
The joint between tiles is segmented into two functional zones: a structural zone occupied by the spacer that provides mechanical strength and alignment, and a protective zone filled with encapsulant that provides weather sealing. This segmentation allows each material to optimize its specific function
2Reliability
If photovoltaic roof tiles are joined with encapsulant-filled gaps, then the tiles are protected from weather elements, but the joints have poor aesthetic appearance
Solution Approach 1:
The spacer acts as a visible intermediary element that defines the joint appearance. It provides a clean, structured visual interface between tiles while the encapsulant remains hidden within the spacer-defined boundaries, creating an aesthetically pleasing joint
3Ease of operation
If electrical connections are exposed between tiles, then inter-tile electrical bussing is facilitated, but the connections are vulnerable to weather damage
Solution Approach 1:
The spacer is positioned beforehand to create a protected pathway for electrical bussing. The encapsulant is then applied to fill spaces and seal around the electrical connections, providing preemptive weather protection before the module is installed on the roof
Solution Approach 2:
The spacer serves as a mediator that organizes and protects electrical connections. It provides a defined channel for bussing while the encapsulant provides an additional protective barrier, shielding electrical components from direct weather exposure
4Ease of manufacture
If multiple tiles are fabricated separately, then manufacturing flexibility is maintained, but assembly complexity and installation time increase
Solution Approach 1:
The spacer is pre-positioned between tiles during the lamination process, and electrical connections are pre-routed through the spacer structure. This preliminary arrangement of components simplifies the subsequent assembly and installation processes
Data Source
AI summary
One embodiment described herein provides a photovoltaic roof module. The roof module can include at least a first photovoltaic roof tile, a second photovoltaic roof tile positioned adjacent to the first photovoltaic roof tile, and a spacer coupled to and positioned between the first and second photovoltaic roof tiles. The spacer is configured to facilitate a semi-rigid joint between the first and second photovoltaic roof tiles.