Offset-Plane Photovoltaic Module Wireway for Steep-Slope Roofs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic modules installed on steep slope roofs face challenges in integrating solar cells with roofing shingles, particularly in forming efficient wireways for electrical components without compromising structural integrity and performance.
Innovation Solution
A method involving laminating or vacuum forming photovoltaic modules with offset planes to create a wireway, using components like frontsheet, solar cells, and backsheet, at specific temperatures and pressures, to form a photovoltaic module with distinct portions extending along different planes, allowing for efficient integration with roofing shingles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If photovoltaic modules are installed on steep slope roofs adjacent to roofing shingles, then integration with roofing system is achieved, but structural integrity and performance are compromised due to difficulty in forming efficient wireways
Solution Approach 1:
The photovoltaic module is divided into distinct portions: a first portion with solar cells arranged in rows for power generation, and a second portion formed as an offset wireway for electrical component integration. This segmentation allows the module to simultaneously achieve roofing integration and maintain structural integrity by separating functional zones.
Solution Approach 2:
The wireway is formed by offsetting the second portion of the module from the first portion, creating a three-dimensional structure that extends along different planes. This dimensional change enables efficient wire routing and electrical component placement while maintaining the module's integration with the roofing system.
2Ease of manufacture
If wireways are formed in traditional flat photovoltaic modules, then electrical components can be integrated, but structural integrity is compromised on steep slope roofs
Solution Approach 1:
The wireway is created by offsetting portions of the module along different planes, transforming a two-dimensional flat structure into a three-dimensional configuration. This allows electrical components to be integrated in the offset portion without compromising the structural integrity of the main solar cell array.
Solution Approach 2:
Different portions of the module have different structural configurations: the first portion maintains a flat structure optimized for solar cell performance, while the second portion is offset to create the wireway. This local differentiation allows electrical integration without affecting the overall structural integrity.
3Ease of manufacture
If photovoltaic modules use coplanar structure, then manufacturing is simplified, but wireway formation for electrical components becomes inefficient
Solution Approach 1:
The module transitions from a coplanar structure to a multi-planar structure with an offset wireway portion. This dimensional change enables efficient wire routing and electrical component placement while maintaining manufacturing feasibility through standardized lamination and forming processes.
Solution Approach 2:
The wireway structure is pre-formed as an integral part of the module during the lamination and forming processes, rather than being added separately. This preliminary action improves wireway formation efficiency while maintaining manufacturing simplicity through integrated processing.
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 method enables effective integration of solar cells with roofing shingles by creating a wireway, enhancing structural integrity and performance of photovoltaic modules on steep slope roofs.
Implementation Method 1
the backsheet has a front surface configured to reflect light incident on the front surface back through the solar cells
Data Source
AI summary
A method, including obtaining a plurality of components, including at least a frontsheet, solar cells, and a backsheet; positioning the plurality of components such that a first row of solar cells is above the backsheet, a second row of solar cells is above the backsheet, and the frontsheet is above at least one of the first row of solar cells or the second row of solar cells; and laminating the plurality of components to form a photovoltaic module. The photovoltaic module includes a first portion and a second portion, where the first portion of the photovoltaic module includes the first row of solar cells, where the second portion of the photovoltaic module includes the second row of solar cells, where the first portion of the photovoltaic module extends along a first plane, where the second portion of the photovoltaic module extends along a second plane, and where the second plane is offset from the first plane.