Solar Shingle Backsheet Seams for Separable Module Wiring

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Solution Overview

Problem

Existing solar shingle technologies face challenges in efficiently integrating and connecting photovoltaic modules with roofing substrates while maintaining electrical insulation and operational efficiency.

Innovation Solution

The method involves attaching photovoltaic modules to a back-sheet, forming a seam and electrical connection, and separating them while maintaining the connection, using a roofing substrate with an adhesive or nailing, and configuring the system with a single junction box and optimizer for efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If photovoltaic modules are attached to a back-sheet and then separated along the seam, then ease of installation and reconfiguration is improved, but maintaining electrical connection during separation becomes more complex

Engineering Contradiction:

Improveease of installationVSAvoidelectrical connection maintenance

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The back-sheet is divided into separate sections with seams that allow individual photovoltaic modules to be separated and repositioned. Each module can be detached along the seam lines while maintaining electrical connections through the segmented structure, enabling modular installation and reconfiguration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Conductive seams or conductive elements within the back-sheet serve as intermediaries that maintain electrical connection between photovoltaic modules during separation and reconfiguration. These intermediary conductive paths ensure continuous electrical flow even when modules are physically separated along the seams.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If multiple photovoltaic modules are integrated with a single junction box and optimizer, then device complexity is reduced, but manufacturing and electrical connection precision requirements increase

Engineering Contradiction:

Improvenumber of componentsVSAvoidelectrical connection precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Multiple photovoltaic modules are electrically merged through a common back-sheet structure that integrates conductive paths to a single junction box and optimizer. This consolidation reduces the number of separate electrical connections needed while maintaining efficient power collection from all modules.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The back-sheet serves multiple functions simultaneously: it provides electrical insulation where needed, creates conductive paths for electrical connections, forms structural seams for module separation, and integrates multiple modules into a unified electrical system with a single junction box and optimizer.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If photovoltaic modules are laminated to the back-sheet, then electrical insulation is improved, but ease of separation and reconfiguration deteriorates

Engineering Contradiction:

Improveelectrical insulationVSAvoidease of separation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The back-sheet exhibits different properties in different locations: areas with photovoltaic modules have insulating characteristics for electrical protection, while seam areas have conductive or separable characteristics that allow easy separation and reconfiguration. This local differentiation of properties resolves the contradiction between insulation and separability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The attachment between photovoltaic modules and back-sheet is designed to be dynamic rather than permanently fixed. The lamination allows electrical insulation during operation while permitting controlled separation along predefined seams when reconfiguration is needed, providing adaptability between stable and separable states.

Inventive Principle:

Principle #15Dynamics

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 approach allows for efficient integration and operation of solar shingles with the roofing substrate, maintaining electrical insulation and operational efficiency, and enabling easy separation and reconfiguration of photovoltaic modules.

Implementation Method 1

the back-sheet may be configured to electrically insulate the first and second photovoltaic modules

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

Some roofing systems include photovoltaic modules

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS11824487B2Photovoltaic module systems and methods

Publication Date: 2023.11.21 GAF ENERGY LLC

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.