Photovoltaic Roof Tile Encapsulation and Interconnection
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Solution Overview
Problem
Packaging high-efficiency solar cells into roof tiles that can withstand extreme weather conditions while ensuring easy installation and protecting electrical interconnections is challenging due to the need for robust weatherproofing and aesthetic appeal.
Innovation Solution
A photovoltaic roof module comprising multiple tiles with encapsulated solar structures, edge busbars for cascaded connections, metallic tabs for electrical coupling, and reinforcement spacers for mechanical stability, along with junction boxes for inter-module connections, facilitating parallel and serial electrical configurations and enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple roof tiles are fabricated together as a module, then ease of installation is improved, but device complexity increases due to the need for electrical interconnections and weatherproofing
Solution Approach 1:
Multiple photovoltaic roof tiles are fabricated together as a single module with integrated electrical interconnections, encapsulant layers, and spacing structures. This merging of multiple functional elements into one pre-assembled unit simplifies installation while managing the inherent complexity through systematic integration.
Solution Approach 2:
The photovoltaic module is segmented into distinct functional components including individual roof tiles with embedded solar cells, spacing structures between tiles, encapsulant layers for sealing, and electrical interconnection elements. This segmentation allows each component to be optimized independently while maintaining overall system functionality.
2Reliability
If electrical interconnections are protected against weather elements, then reliability is improved, but device complexity increases due to additional protective structures
Solution Approach 1:
An encapsulant layer is used to create a flexible protective seal around the electrical interconnections and solar cells. This thin film structure provides weatherproofing and protection against environmental elements while maintaining the electrical functionality and avoiding rigid complex protective structures.
Solution Approach 2:
The electrical interconnections are nested within the encapsulant layer, which itself is nested between the front and back covers of the module. This nested arrangement protects the electrical components through multiple layers while maintaining a compact overall structure.
3Reliability
If photovoltaic structures are encapsulated between front and back covers, then protection from weather elements is improved, but manufacturing precision requirements increase
Solution Approach 1:
The encapsulant material properties are optimized to provide adequate sealing and protection while accommodating normal manufacturing tolerances. By adjusting the material parameters such as viscosity, curing characteristics, and expansion properties, the system achieves reliable weatherproofing without requiring extreme manufacturing precision.
Data Source
AI summary
One embodiment can provide a photovoltaic roof module. The photovoltaic roof module can include a plurality photovoltaic roof tiles. A respective photovoltaic roof tile can include a glass front cover, a back cover that includes glass of photovoltaic backsheet, and a plurality of photovoltaic structures encapsulated between the glass front cover and the back cover by an encapsulant. The photovoltaic roof tile can be configured to function as a roof tile when placed on a rooftop of a building, thereby protecting the building from weather elements.