Solar Shingle Backsheet Seams for Connected Module Installation
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Solution Overview
Problem
Existing solar shingle roofing systems face challenges in efficiently integrating and connecting photovoltaic modules to a roofing substrate while maintaining electrical insulation and ease of installation.
Innovation Solution
A method involving attaching photovoltaic modules to a back-sheet, forming a seam, and creating an electrical connection between them, which allows for separation while maintaining the connection, using a single junction box and optimizer, and attaching the back-sheet to a roofing substrate with adhesives or nails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photovoltaic modules are attached to a back-sheet with multiple connection points, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The back-sheet is segmented into multiple sections, each with its own connection points for photovoltaic modules. This segmentation allows electrical connections to be made at multiple discrete locations along the back-sheet, improving connection reliability while maintaining manageable manufacturing complexity through modular assembly
Solution Approach 2:
The back-sheet serves multiple functions: it provides electrical insulation between modules, structural support for attaching photovoltaic modules, and a substrate for forming seams. This multi-functionality reduces the need for separate components, simplifying manufacturing while maintaining reliable electrical connections
2Stability of the object's composition
If photovoltaic modules are permanently bonded to the back-sheet, then structural stability is improved, but ease of repair deteriorates
Solution Approach 1:
The attachment system transitions from a static permanent bond to a dynamic reversible connection. Photovoltaic modules are attached to the back-sheet using removable fasteners or mechanical attachment points that provide structural stability during operation but allow for easy removal and replacement when repair is needed
Solution Approach 2:
The design allows individual photovoltaic modules to be easily removed from the back-sheet without damaging the back-sheet itself. Defective modules can be discarded and replaced with new ones, while the back-sheet and its attachment infrastructure are recovered and reused, simplifying repair processes
3Area of stationary object
If photovoltaic modules are closely spaced on the back-sheet, then area utilization is improved, but heat dissipation deteriorates
Solution Approach 1:
The back-sheet incorporates regions with different thermal properties. Areas between closely spaced photovoltaic modules have enhanced thermal conductivity or air circulation channels that facilitate heat dissipation, while the photovoltaic module attachment areas maintain close spacing for optimal area utilization. This local differentiation of thermal quality allows both goals to be achieved
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
This method enables efficient integration and connection of photovoltaic modules, ensuring electrical insulation and ease of installation, allowing for flexible configuration and operation of solar shingles as a roofing system.
Implementation Method 1
the back-sheet may be configured to electrically insulate the first and second photovoltaic modules
Implementation Method 2
using an adhesive to attach the back-sheet to a roofing substrate
Data Source
AI summary
Some embodiments of the present disclosure relate to methods that may include attaching a first photovoltaic module and a second photovoltaic module to a back-sheet, wherein the first photovoltaic module includes a first end and a second end, and wherein the second photovoltaic module includes a first end and a second end; forming a seam on the back-sheet between the first and second photovoltaic modules; forming an electrical connection between the first and second photovoltaic modules by electrically connecting the first end of the first photovoltaic module to the second end of the second photovoltaic module; and separating the first and second photovoltaic modules along the seam while maintaining the electrical connection between the first and second photovoltaic modules. Some embodiments of the present disclosure relate to roofing systems that may include photovoltaic modules.