Photovoltaic Module Wear Indicator Coating
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Solution Overview
Problem
Conventional photovoltaic modules are prone to damage and deterioration, particularly in applications like vehicle and building integration, leading to irreversible loss of functionality and the need for full module replacement, without options for maintaining optimal light reception or aesthetic modification.
Innovation Solution
A photovoltaic device with a sacrificial coating layer that allows for wear indication and refurbishment, enabling the module to maintain functionality even after damage, and allowing for aesthetic changes without replacing the entire module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional photovoltaic module is used without a sacrificial coating layer, then the module structure is simple and manufacturing cost is low, but the module is prone to damage and deterioration leading to irreversible loss of functionality
Solution Approach 1:
The photovoltaic module is segmented into functional layers: the photovoltaic cells enclosed in encapsulation material form the core functional unit, while the sacrificial coating layer forms a separate protective outer layer. This segmentation allows the coating to be replaced independently without damaging the expensive photovoltaic cells, thus maintaining reliability while managing complexity through functional separation.
Solution Approach 2:
The sacrificial coating layer acts as a beforehand cushion against mechanical damage, wear, and environmental deterioration. It is designed to be the first line of defense that absorbs damage before it reaches the photovoltaic cells, thereby protecting the core functionality and extending module life.
2Reliability
If the entire photovoltaic module is replaced when the front face is damaged, then functionality is restored, but material waste increases and cost rises
Solution Approach 1:
The sacrificial coating layer is extracted as a replaceable component that can be removed and replaced independently from the photovoltaic cells. When the coating becomes damaged or worn, only the coating layer needs to be taken off and replaced, leaving the functional photovoltaic cells intact and reusable, thereby reducing material waste.
Solution Approach 2:
The sacrificial coating layer is designed to be discarded when damaged, while the valuable photovoltaic cells are recovered and retained for continued use. This approach allows selective replacement of only the consumable protective layer, minimizing waste of functional materials.
3Reliability
If the front face of the photovoltaic module is sanded to restore functionality, then light reception is improved, but the risk of damaging the module increases without wear indicators
Solution Approach 1:
The wear indicators incorporate color-changing or visually distinct features that signal the remaining thickness of the sacrificial coating layer. As the coating is sanded down, the wear indicators become visible or change appearance, providing real-time feedback to operators about how much material remains before the critical threshold is reached, thereby preventing accidental damage.
Solution Approach 2:
The wear indicators provide continuous visual feedback during the sanding process, allowing operators to monitor the coating thickness and stop sanding at the appropriate point. This feedback mechanism eliminates the need for complex measurement equipment and prevents over-sanding that could damage the underlying photovoltaic cells.
4Strength
If a thick front face glass is used to increase mechanical strength, then the module is more durable, but the weight and manufacturing cost increase
Solution Approach 1:
The sacrificial coating layer functions as a thin protective film that provides mechanical protection and durability without the weight of thick glass. This thin film approach maintains adequate strength for the application while significantly reducing weight compared to using thick front face glass.
Solution Approach 2:
The photovoltaic module uses a composite structure combining the sacrificial coating layer with the front face glass or polymer substrate. This composite approach optimizes the balance between strength, weight, and replaceability, allowing the coating to provide protective function while the underlying structure provides structural support.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5i
AI summary
The main object of the invention is a photovoltaic device (10), comprising: one or more photovoltaic modules (1), each photovoltaic module (1) having a first transparent layer (2) forming the front face, intended to receive a luminous flux, a plurality of photovoltaic cells (4), an assembly encapsulating (3) the plurality of photovoltaic cells (4), and a second layer (5) forming the rear face; at least one coating layer (7) disposed on the first layer (2) of the or each photovoltaic module (1), the photovoltaic device (10) having at least one wear indicator (11) integrated in said at least one coating layer (7) and visible through said at least one coating layer (7).