Photovoltaic Module Segmentation for Custom Installation
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Solution Overview
Problem
Existing photovoltaic module installations face challenges in flexibility, adaptability to local conditions, and ease of mounting on roofs and facades, often requiring standard sizes that do not fit non-standard areas, leading to complex and costly installations.
Innovation Solution
A photovoltaic module design featuring a plate-shaped support with a high percentage of inactive area that can be customized in size and shape by cutting, allowing for flexible installation without affecting the active solar cell functionality, using a terminal box interface and embedding solar cells in a layer structure with encapsulant layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If photovoltaic modules are produced in standard sizes, then manufacturing and logistics are simplified, but adaptability to non-standard roof and facade areas is reduced
Solution Approach 1:
The photovoltaic module is divided into two distinct functional zones: an active area containing solar cells for energy generation, and an inactive area without solar cells that serves as a customizable region. This segmentation allows the inactive area to be cut or broken to various shapes and sizes while the active area remains intact, enabling adaptation to non-standard installation surfaces while maintaining standardized manufacturing processes for the core functional components.
Solution Approach 2:
Different regions of the module are assigned different properties: the active area is optimized for photovoltaic functionality with solar cells and associated layers, while the inactive area is designed to be cuttable and breakable without affecting the active area. This local differentiation enables the module to maintain standardized production for the functional core while allowing customization at the installation site through modification of the inactive region.
2Adaptability or versatility
If the area of inactive area is increased to at least 20% of the active area, then flexibility for on-site customization is improved, but the proportion of energy-generating area is reduced
Solution Approach 1:
The module includes an inactive area that exceeds the minimum necessary for basic functionality, providing excess material that can be removed at the installation site. This excessive inactive area (at least 20% of the active area) acts as a buffer zone that can be cut or broken to achieve precise fits for various installation geometries without risking damage to the active area, thereby enabling customization while maintaining a reasonable proportion of functional solar cells.
3Adaptability or versatility
If photovoltaic modules are cut or broken to fit non-standard areas, then adaptability to local conditions is improved, but structural integrity and reliability may be compromised
Solution Approach 1:
The inactive area is specifically designed to be the region that can be removed through cutting or breaking operations. By extracting this non-functional material from the module structure, installers can adapt the module shape without compromising the integrity of the active area, which contains the solar cells and critical functional layers. The inactive area serves as a sacrificial zone that absorbs the mechanical stress of customization operations.
Solution Approach 2:
The module is pre-configured with a sufficient inactive area (at least 20% of active area) during manufacturing, preparing it in advance for potential on-site customization. This preliminary provision of excess inactive material ensures that when cutting or breaking is required at the installation site, the active area is already protected and positioned to remain intact, thereby maintaining reliability while enabling adaptability.
4Quantity of substance
If photovoltaic modules cover complete available areas, then energy generation capacity is maximized, but installation complexity increases for non-standard geometries
Solution Approach 1:
By segmenting the module into active and inactive areas, the invention simplifies the installation process for non-standard geometries. Installers can directly cut or break the inactive area of individual modules to match the available surface geometry, eliminating the need for complex arrangements of multiple standard modules or custom fabrication. This segmentation approach enables straightforward adaptation while maintaining maximum coverage of the available installation area.
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
Enables easy, reliable, and aesthetically pleasing installation of photovoltaic systems on various structures by allowing on-site customization of module size and shape, simplifying manufacturing and logistics, while maintaining photovoltaic functionality and optical homogeneity.
Implementation Method 1
a photovoltaic module (1) comprising a plate-shaped support (5) and solar cells (6) carried by the plate-shaped support (5) and connected to an electric interface (7)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a photovoltaic module (1) comprising a plate-shaped support (5) and solar cells (6) carried by the plate-shaped support and connected to an electric interface (7), preferably in form of a terminal box, wherein on the front side the area of the photovoltaic module (1) is divided into photovoltaic active area (2) and inactive area (3), wherein the area of inactive area (3) of the photovoltaic module (1) amounts to at least 20%, preferably to at least 40%, more preferred to at least 80%, of the area of photovoltaic active area (2) of the photovoltaic module (1).