Partially Translucent Photovoltaic Modules Segmentation
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Solution Overview
Problem
Current methods for fabricating photovoltaic modules are limited to small sizes, such as 150 cm by 60 cm, which are not suitable for building-integrated applications requiring larger, non-standard sizes like 2 to 4 meters by 1 to 2 meters, and there is a need for partially translucent or transparent modules to meet architectural requirements.
Innovation Solution
A method for electrically interconnecting multiple thin-film photovoltaic plates of varying sizes up to 4 meters by 2 meters, using a grid structure of electrically conductive wires with optically transparent insulating layers to form busbar connections, allowing for parallel or series interconnections, and encapsulating the modules between sheets to achieve desired sizes and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If thin-film photovoltaic modules are fabricated using conventional equipment, then the modules can be produced with standard sizes, but the module size is limited to relatively small dimensions (e.g., 150 cm by 60 cm) which are not suitable for building-integrated applications
Solution Approach 1:
The photovoltaic module is divided into multiple separately fabricable thin-film photovoltaic plates that can be produced using conventional equipment and then assembled together. Each plate can be manufactured within the capabilities of standard equipment, and multiple plates are combined to achieve the desired large overall module size for building-integrated applications.
2Area of stationary object
If photovoltaic modules are made larger to suit building-integrated applications, then the modules can cover larger areas, but the equipment used for fabrication must be upgraded or replaced
Solution Approach 1:
The large-area photovoltaic module is segmented into multiple smaller thin-film photovoltaic plates that can each be fabricated using conventional equipment. This segmentation allows the use of existing manufacturing equipment while achieving the desired large total area through assembly of multiple plates.
Solution Approach 2:
Multiple separately fabricated thin-film photovoltaic plates are merged or assembled together to form a large-area photovoltaic module. This combining approach enables the achievement of large module areas suitable for building-integrated applications without requiring upgrades to fabrication equipment.
3Adaptability or versatility
If photovoltaic modules are made translucent to meet architectural requirements, then the aesthetic and functional needs of building integration are satisfied, but the manufacturing process becomes more complex
Solution Approach 1:
The thin-film photovoltaic plates are designed with local quality variations, including translucent regions that allow light transmission and opaque regions containing the photovoltaic active layers. This local differentiation enables the module to meet architectural translucency requirements while maintaining photovoltaic functionality in specific areas.
Solution Approach 2:
The module is segmented into multiple thin-film photovoltaic plates, each with controlled translucency properties. This segmentation allows for optimized optical and electrical design of each individual plate while meeting the overall architectural requirements for building integration.
4Length of stationary object
If multiple thin-film photovoltaic plates are electrically interconnected to form large modules, then the desired module size and output are achieved, but the number of manufacturing steps increases
Solution Approach 1:
Electrical interconnection elements are provided on the thin-film photovoltaic plates in advance, before the final assembly of the module. This preliminary preparation of electrical connections on individual plates simplifies the subsequent assembly process and enables more efficient manufacturing of large modular photovoltaic systems.
Solution Approach 2:
Multiple thin-film photovoltaic plates with pre-prepared electrical interconnection elements are combined through simplified assembly processes. This merging approach reduces the overall number of manufacturing steps required compared to creating electrical connections during final assembly, thereby improving manufacturing efficiency.
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
Enables the production of large, partially translucent or transparent photovoltaic modules with uniform appearance, independent output voltage, and cost-effective manufacturing, suitable for building-integrated applications, while reducing manufacturing steps and labor costs.
Implementation Method 1
using a grid structure of electrically conductive wires with optically transparent insulating layers
Implementation Method 2
thin-film photovoltaic plates... each comprising at least one first plate electrode of a first polarity and at least one second plate electrode of a second polarity opposite to the first polarity
Data Source
AI summary
Example embodiments relate to partially translucent photovoltaic modules and methods for manufacturing partially translucent photovoltaic modules. One embodiment includes a method for electrically interconnecting a plurality of thin-film photovoltaic plates. The method includes positioning a plurality of thin-film photovoltaic plates side by side. The thin-film photovoltaic plates are partially translucent or non-translucent. The method also includes providing at least one connection element on a surface of each of the plurality of thin-film photovoltaic plates. The at least one connection element includes a plurality of electrically conductive wires arranged in a grid structure. Further, the method includes physically separating each connection element into a first connection part that includes a plurality of first electrically interconnected, conductive wires and a second connection part that includes a plurality of second electrically interconnected, conductive wires. In addition, the method includes providing busbars and forming electrical busbar connections.