Photovoltaic Foil with Integrated Conductive Layer Stack for Roof Installation
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Solution Overview
Problem
The installation of photovoltaic systems is time-consuming due to the need for precise connection of solar panels to achieve the proper input voltage for power conversion modules, especially on roofs of varying sizes and shapes.
Innovation Solution
A photovoltaic product comprising a foil with a photovoltaic layer stack and an electrically conductive layer stack, where the conductive layer stack includes distinct contact areas and vias for easy interconnection, allowing for flexible installation on arbitrary-sized roofs with a predetermined output voltage and adjustable current delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solar panels are properly connected to achieve the proper input voltage for power conversion modules, then the system reliability is improved, but the installation time increases
Solution Approach 1:
The photovoltaic product is divided into modular units with standardized electrical connections. Each module contains photovoltaic elements arranged in series to provide a predetermined output voltage, with integrated contact areas and connection elements that simplify inter-module connections. This segmentation allows rapid assembly while maintaining system reliability through standardized interfaces.
Solution Approach 2:
The electrical connections and circuitry are pre-configured within each photovoltaic module during manufacturing. The contact areas, conductive layers, and connection elements are prepared in advance with correct polarity and voltage configuration, eliminating the need for complex on-site wiring and voltage matching during installation.
2Reliability
If the photovoltaic product is designed with large contact areas for low resistance connections, then the electrical conductivity is improved, but the manufacturing complexity increases
Solution Approach 1:
Multiple functional elements are merged into integrated structures. The contact areas are formed as continuous conductive regions that serve both as electrical contacts and as part of the structural substrate. The first and second electrically conductive layers are integrated with the photovoltaic elements and insulation layers in a unified stack, reducing the number of separate manufacturing steps.
Solution Approach 2:
The electrical conductivity is optimized by controlling the parameters of the conductive layers, including material composition, thickness, and lateral dimensions of contact areas. The vias are designed with specific diameter and depth parameters to achieve low resistance connections while maintaining manufacturability through standard fabrication processes.
3Adaptability or versatility
If the photovoltaic product allows flexible installation on arbitrary-sized roofs, then the adaptability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The photovoltaic module is designed with universal connection interfaces that can accommodate various installation configurations and roof sizes. The first and second electrically conductive layers with their respective contact areas and background domains provide standardized connection points that work regardless of the number of modules connected or their arrangement, enabling flexible system scaling.
Solution Approach 2:
The electrical connections are designed with localized contact areas that have enhanced dimensions and properties specifically at the connection points. The contact areas are laterally extended and positioned at specific locations on the conductive layers, providing robust electrical connection zones that tolerate minor positioning variations during installation while maintaining connection precision where it matters most.
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
Facilitates efficient and easy installation on roofs of any dimension, ensuring a fixed output voltage regardless of the panel size, with large contact areas for low resistance connections and diodes to prevent energy loss and damage from non-functional units.
Implementation Method 1
a photovoltaic product (1) that comprises a foil with a photovoltaic layer stack (10) and an electrically conductive layer stack (20)... provides for a transport of electric energy generated by the photovoltaic layer stack (10) to an external load
Implementation Method 2
a first plurality of laterally distributed electrically conducting vias (24) that electrically interconnect respective ones of the first plurality of contact areas (211) with the second electrically conductive background domain (220)
Data Source
Figure 1A
Figure 1B
Figure 2A~2AB
AI summary
The present disclosure pertains to a photovoltaic product (1), comprising a foil with a photovoltaic layer stack (10) and an electrically conductive layer stack (20) that supports the photovoltaic layer stack and that in an operational state provides for a transport of electric energy generated by the photovoltaic layer stack to an external load. The electrically conductive layer stack (20) comprises a first and a second electrically conductive layer (21, 22) and an electrically insulating layer (23) arranged between the first and the second electrically conductive layer, wherein the photovoltaic layer stack (10) has first electrical contacts (PI, P2) of a first polarity that are electrically connected to the first electrically conductive background domain (210) and has second electrical contacts (Nl, N2) of a second polarity opposite to said first polarity that are electrically connected to the first contact areas (211), and wherein the second electrically conductive background domain (220) and one or more of the second contact areas (221) serve as electric contacts for the output clamps.