PV Facade Panel Lamination for Large Glass Integration
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Solution Overview
Problem
Conventional photovoltaic modules are limited in size, making it difficult to create large, aesthetically pleasing, and resource-efficient facade elements that integrate energy generation with building design, while also ensuring quick and environmentally friendly manufacturing and long durability.
Innovation Solution
A facade plate design featuring a monolithic glass carrier with integrated photovoltaic modules, where the modules are connected using a tempered vacuum process and autoclave method, allowing for oversized and flexible solar cells that are encapsulated and electrically connected, providing a static self-supporting structure with high transparency and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional photovoltaic modules are used, then energy generation function is achieved, but the facade element size is limited and aesthetic integration is compromised
Solution Approach 1:
The patent merges multiple photovoltaic modules into a single integrated facade element by bonding them to a common carrier glass. This allows the creation of large-area facade elements (exceeding 1.5m x 1.5m) while maintaining the energy generation function of the PV modules. The modules are arranged in a matrix pattern and bonded using adhesive or lamination techniques, creating a unified aesthetic appearance that integrates seamlessly with the building facade.
2Productivity
If photovoltaic modules are integrated into facade, then energy generation is achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent employs preliminary action by pre-assembling and pre-testing the photovoltaic modules before integrating them into the final facade element. The modules are arranged in the desired matrix pattern on the carrier glass and pre-bonded in a controlled manufacturing environment. This allows for quality control and assembly optimization before the element is installed on the building, thereby improving manufacturing efficiency and reducing on-site installation complexity.
3Illumination intensity
If conventional PV modules are used, then energy generation is achieved, but aesthetic appearance and transparency are compromised
Solution Approach 1:
The patent applies local quality by using transparent or semi-transparent photovoltaic modules that allow light to pass through while still generating electricity. The transparent layer covering the PV cells enables the facade to maintain its aesthetic appearance and transparency requirements. The arrangement of modules in a matrix pattern on the carrier glass creates a uniform appearance that can be customized to match different architectural designs, thereby achieving both aesthetic integration and energy generation.
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 the production of oversized, aesthetically integrated photovoltaic facade elements that match large glass panel sizes, offering high energy yield, durability, and resource-saving operation while maintaining a sleek, undetectable appearance from the outside.
Implementation Method 1
Each structural element comprises a support in the form of a monolithic glass panel (1) having an upper side (2) that forms the outer side of the structural element, in particular of the facade panel, and a plurality of photovoltaic modules (3) arranged in a row or in an array, wherein the photovoltaic modules (3) are laminated onto an underside of the carrier (2)
Implementation Method 2
the photovoltaic modules (3) are laminated onto an underside of the carrier (2) opposite the upper side (2) in the course of an autoclave process
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a structural element (1) in the form of a facade panel, in particular one with a sandwich-like structure. The structural element (1) has a support in the form of a monolithic glass panel (2), which has a top surface that forms the outer surface of the structural element (1), which is designed in particular as a facade panel. The structural element (1) further comprises a plurality of photovoltaic modules (3) arranged in a row or in an array. According to the invention, it is particularly provided that the photovoltaic modules (3) are laminated onto a bottom surface of the support (2), opposite the top surface, in a material-bonded manner, particularly during an autoclave process.