Semi-elastic Photovoltaic Module with MWT Cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic modules face inefficiencies in converting solar radiation to electric power, mechanical strength, weight, and aesthetic limitations, particularly when installed on curved surfaces or used in Building-Integrated Photovoltaics (BIPV) applications.
Innovation Solution
A semi-elastic photovoltaic module design utilizing ultra-thin chemically strengthened glass panes and amorphous encapsulants with monocrystalline cells made via Metal Wrap Through (MWT) technology, featuring a current-conducting film with by-pass diodes and a rigid frame for enhanced efficiency, mechanical strength, and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid glass and metal frames are used in photovoltaic modules, then mechanical strength is improved, but weight increases and adaptability to curved surfaces decreases
Solution Approach 1:
The patent replaces traditional rigid glass panes with thin-film photovoltaic structures that can be bent to curved surfaces. The module employs flexible substrate materials and thin-film encapsulation layers that maintain structural integrity while enabling adaptation to non-planar surfaces, thus resolving the contradiction between mechanical strength and adaptability to curved surfaces.
Solution Approach 2:
The patent specifically designs the photovoltaic module to accommodate curved surfaces by incorporating flexible structural elements that can conform to cylindrical and other non-planar geometries. This enables installation on curved roofs and surfaces while maintaining the module's mechanical strength through appropriate material selection and structural design.
2Strength
If traditional photovoltaic module structures are used, then mechanical strength is maintained, but weight reduction and aesthetic qualities for BIPV applications are limited
Solution Approach 1:
The patent employs thin-film photovoltaic structures with flexible substrates that significantly reduce module weight compared to traditional rigid glass and metal frame constructions. The thin-film encapsulation and flexible support structures maintain adequate mechanical strength while enabling weight reduction for applications such as curved roofs and portable installations.
Solution Approach 2:
The patent changes the physical parameters of the module structure by transitioning from thick rigid glass panes to thin-film structures with reduced thickness and density. This parameter change achieves weight reduction while maintaining mechanical strength through appropriate material selection and structural optimization.
3Ease of manufacture
If conventional photovoltaic cell connections are used, then manufacturing simplicity is maintained, but conversion efficiency and Fill Factor are suboptimal
Solution Approach 1:
The patent extracts and eliminates the transparent conductive oxide (TCO) layer from the photovoltaic cell structure. By removing this layer, the design achieves lower series resistance and improved Fill Factor while maintaining manufacturing feasibility through alternative contact configurations that directly connect metal contacts to the semiconductor without requiring TCO.
Solution Approach 2:
The patent inverts the traditional connection approach by using metal wrap-through contacts that extend through the cell structure rather than relying on TCO-based surface contacts. This inversion of the contact scheme reduces series resistance and improves efficiency while maintaining manufacturing simplicity through established metal deposition and patterning techniques.
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 significantly improves solar radiation conversion efficiency, reduces module weight, enhances mechanical strength, and allows installation on curved surfaces while maintaining high aesthetic qualities suitable for BIPV applications, with improved Fill Factor and reduced material costs.
Implementation Method 1
upper outer transparent glass pane and lower outer glass pane, each of them 0.5-1.35-mm thick and chemically strengthened in potassium salt bath
Implementation Method 2
monocrystalline photovoltaic cells, made preferably with the use of Metal Wrap Through (MWT) technology
Implementation Method 3
two amorphous film encapsulants, each 0.5-0.8-mm thick
Implementation Method 4
The current-conducting film is provided with negative electrodes and positive electrodes on its surface
Implementation Method 5
by-pass diodes connected with said film by means of epoxy binder
Implementation Method 6
all components of the module are laminated together constituting a monolithic structure
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The subject of the invention is a semi-elastic photovoltaic module comprising a set of photovoltaic cells placed between two EVA film encapsulants, of which one is covered with a strengthened glass pane, and the other with an electrically insulating film provided with connectors and a connection cable, whereas all these components are hermetically laminated together and set in a rigid aluminium frame, characterised in that it has an upper outer transparent glass pane (1) and a lower outer glass pane (2), each of them 0.5-1.35-mm thick and chemically strengthened; further, two amorphous film encapsulants (3 and 4), each of them 0.5-0.8-mm thick; and monocrystalline or polycrystalline photovoltaic cells (8) placed between the film encapsulant (3) and a current-conducting film (5), said cells manufactured preferably with the use of Metal Wrap Through (MWT) technology. The surface of the current-conducting film (5) is provided with negative electrodes (7) and positive electrodes (6), on which, through perforation holes provided in the cells, base contacts (13) and emitters (12) of the cells, respectively, are put over, while between the emitters and the base contacts there is a coat of a current-conducting binder-adhesive (14) applied with some isolated non-conducting areas (15), said coat connecting the contacts with the current-conducting film (5), and all components of the module are laminated together constituting thus a monolithic structure.