Photovoltaic Roof Tile Encapsulation and Interconnection
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Solution Overview
Problem
Packaging high-efficiency solar cells into photovoltaic 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 integration.
Innovation Solution
A photovoltaic roof module comprising multiple tiles with encapsulated solar strips forming serially connected strings, electrically coupled in parallel, and secured with metallic tabs and strain-relief connectors, along with inter-tile spacers for mechanical stability and encapsulant management, facilitating efficient electrical connections and weather protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple photovoltaic structures are encapsulated between front and back covers to form a roof module, then weather protection and electrical connection reliability are improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The photovoltaic module is segmented into multiple discrete photovoltaic structures (solar cells, strips, or tiles) that can be individually manufactured and then assembled into a complete module. This segmentation allows for standardized production of individual units while maintaining the ability to create complex weatherproof assemblies with proper electrical interconnections through encapsulants and junction boxes.
2Productivity
If photovoltaic structures are arranged in cascaded strings with overlapping edge busbars, then electrical connection efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
Adjacent photovoltaic structures are merged through overlapping edge busbars that create electrical connections between units. The encapsulant material merges these overlapping regions, providing both electrical conductivity and environmental sealing. This merging approach simplifies the manufacturing process by allowing tolerances in individual unit placement while maintaining overall electrical connection efficiency through the combined structure.
3Stability of the object's composition
If tile spacers are used to mechanically couple adjacent roof tiles, then structural stability is improved, but device complexity increases
Solution Approach 1:
The tile spacers serve multiple functions simultaneously: they provide mechanical coupling between adjacent tiles for structural stability, create consistent spacing for aesthetic uniformity, and facilitate water drainage channels. By combining these multiple functions into a single component, the overall device complexity is minimized while achieving enhanced structural performance.
4Reliability
If strain-relief connectors are used to couple metallic tabs to edge busbars, then electrical connection durability is improved, but manufacturing complexity increases
Solution Approach 1:
Strain-relief connectors serve as intermediary components between the metallic tabs and edge busbars. These connectors absorb mechanical stress and thermal expansion differences, protecting the electrical connection from damage. The intermediary nature of these connectors allows for simpler attachment methods while maintaining connection durability, as they can be attached through standardized processes like adhesive bonding or mechanical fastening.
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 solution enables robust, efficient, and aesthetically pleasing integration of high-efficiency solar cells into roof tiles, enhancing durability and installation ease while maintaining electrical integrity under various weather conditions.
Implementation Method 1
photovoltaic (PV) modules, also called PV or solar panels, that can include a two-dimensional array (e.g., 6x12) of solar cells
Implementation Method 2
a plurality of photovoltaic structures encapsulated between the glass front cover and the back cover by an encapsulant
Implementation Method 3
a strain-relief connector, which can include an elongated member and a plurality of laterally extended wires
Data Source
Figure 1
Figure 2A
Figure 2B
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.