DK179442B1

DK179442B1 - A photovoltaic cladding strip and methods of manufacture

Info

Publication number: DK179442B1
Application number: DKPA201700051A
Authority: DK
Inventors: Ursing Jakob
Original assignee: Ursing Jakob
Priority date: 2017-01-25
Filing date: 2017-01-25
Publication date: 2018-09-12
Also published as: SE1830010A1; SE541929C2; DK201700051A1

Abstract

An integrated solar cladding strip (1) comprising a substrate (2) of a roofing membrane, a first layer of an encapsulant (3), a single electric circuit (4) comprising strings of solar cells (5) connected to a single in- and outlet, a second layer of an encapsulant (11), a single sheet of a transparent foil (12) covering the entire circuit (4), a third layer of a hot-melt adhesive encapsulant (13) and a plurality of rigid transparent tiles (14) characterized by that said tiles are positioned over one or more cells (5) forming rigid groups spaced from each other with flexible gaps (15) that are positioned over tab wires (6) that run alone between the cells.

Description

(¹⁹) DANMARK (10)

(12)

PATENTSKRIFT

Patent- og Varemærkestyrelsen (51) Int.CI.: H02S 30/20 (2014.01) E04D13/18 (2018.01) (21) Ansøgningsnummer: PA 2017 00051 (22) Indleveringsdato: 2017-01-25 (24) Løbedag: 2017-01-25 (41) Aim. tilgængelig: 2018-07-26 (45) Patentets meddelelse bkg. og publiceret den: 2018-09-12 (73) Patenthaver:

Jakob Ursing, Gothersgade 139,4.sal, 1123 København K, Danmark (72) Opfinder:

Jakob Ursing, Gothersgade 139,4.sal, 1123 København K, Danmark (54) Titel: A PHOTOVOLTAIC CLADDING STRIP AND METHODS OF MANUFACTURE (56) Fremdragne publikationer:

WO 2008/157803 A1

EP 2277693 A1

EP 1938964 A1

WO 2014189391 A1 (57) Sammendrag:

Fortsættes...

A PHOTOVOLTAIC CLADDING STRIP AND METHODS OF MANUFACTURE

Present invention relates to an integrated photovoltaic strip used for cladding as per claim one, comprising a substrate of a waterproof roofing membrane, a single electric circuit comprising strings of solar cells encapsulated by a first and a second layer of encapsulant, a transparent plastic foil covering the entire circuit, a third layer of an encapsulant and a plurality of rigid transparent tiles characterized by that said tiles are positioned over one or more cells forming rigid groups spaced from each other with flexible gaps that are positioned over wires that run unsupported between the stringed cells.

BACKGROUND OF THE INVENTION

Building Integrated Photo Voltaics (BIPV) is an interesting field for construction professionals such as architects and engineers based on a sound and sustainable idea to use the vast areas of residential buildings with many millions of roof square meters for small solar power plants. In many BIPV installations on pitched roofs the building material, in which the panel or the frameless laminate is integrated, has the sole function of a decorative support whereas the membrane laid under the BIPVs carries out the actual water protection of the building part.

In recent years however, a subgroup of BIPVs has been proposed integrating solar cells in water protecting membranes. Several arguments have been made for this, for example that membrane-integrated systems are saving time by eliminating the need of panel supporting structures. Another argument is the gain of installing several interconnected circuits at one time needing fewer junction boxes. Yet another argument is the possibility of installing the membrane directly onto the substrate of the roof providing the primary waterproofing layer of the roof, itself.

With regards to the manufacturing there are basically two distinctive sets of encapsulant materials depending on whether the facing is a rigid glass sheet or a flexible transparent plastic sheet. Glass faced solar laminates normally use hot-melt based lamination involving various layers of ethylene vinyl acetates (EVA) encapsulants whereas plastic sheet lamination involves glassfiber reinforced epoxy based encapsulants. Furthermore, some membrane-integrated photovoltaics are manufactured in two steps involving the mounting of one or more prelaminated circuits onto a roofing membrane, but others involve the lamination of all components, including the roofing membrane, in a single step.

Patents US4860509 and W02004/066324 contemplate some two-step manufacturing where pre-laminated flexible modules with transparent plastic facing sheets are mounted onto roofing membranes wherein the membranes serve as the primary waterproofing layer for the roof. US2016/0254404 specifically involves an epoxy encapsulant reinforced with glass-fiber scrims. The use of a relatively soft flexible plastic facing present a problem. The facing may for example be insufficient in protecting the laminate from scratches or staining during its operational life. Furthermore, it may present problems in protecting the circuit of solar cells from the damaging impact of hail. Finally, the glass-fiber reinforcing preventing crystalline cells from cracking presents the problem of limited bending, rolling or folding for efficient packing and shipment. Some of these concerns have been addressed in US5482569 where glass tiles are fixed to the laminate after the membrane has been installed to the roof. Unfortunately, this approach rockets the overall cost of the installation.

In patent US2008245405 Garvison et. al. proposes a waterproofing system where the facing is a rigid glass sheet. A laminate is contemplated where a substrate strip of roofing membrane has a first layer of bonding material laid on the substrate onto which a group/circuit of pre-wired photovoltaic cells are positioned. A second layer of bonding material is applied and individual rigid sheets of glass are laid on the second bonding layer, one sheet over each circuit of photovoltaic cells. Some manufacturers propose additional moisture protection to above-mentioned substrate, for example OC3's system Solarion, starting with an extra layer of bonding material onto which an opaque white plastic foil is positioned.

The patent's use of one circuit with one inlet and one output for every single rigid transparent sheet, present a problem when sheets are as small as a roof tile i.e. the area of one or a few cells. The system will prove costly, especially when the pattern of glass sheets is having the scale of a tiled roof characterized by relatively short distance between gaps, by offset gaps and sometimes by narrow gap widths. Solving this problem by simply cutting the glass sheet into smaller tiles covering a few cells, but otherwise keeping the layering of the assembly, would leave unprotected gaps over some wires (called positive and negative lead) in the middle of a circuit (called group) and would certainly not solve the problem of protecting the circuit from humidity posed by e.g. the wet leakage current test in the international standard IEC 61215:2005. Neither would the covering of these gaps with a narrow strip of protective tedlar™/polyester between the glass tiles as suggested, since humidity and leaking electricity may travel through the thin layer of encapsulant along the sides of the narrow strip.

Other patents have also been identified as close prior art in patent databases concerning either solutions with rigid pieces or flexible solutions. No mixing of the two main concepts has been identified. WO 208/157803 by SOLAR INTEGRATED TECHNOLOGIES, concerns a PV panel including a plurality of rigid PV modules attached sideby-side. However, only a passage in the abstract concerns rigid PV modules, thus teaching away from rigid transparent tiles as of the claims of the present invention. The patent EP 2277693 by RENOLIT concerns foldability of PV modules. The document I split between either solution with rigid pieces or flexible solutions. No combination of the two is devised. Patent EP 1938964 by DU PONT, concerns PV panels without mentioning rolling them as roofing materials. Patent WO2014189391 by ZINNIATEK, show figures of roofing panels without mentioning hot-melt adhesives.

Accordingly, a need exists for an elongated strip of a roofing membrane with a single circuit of interconnected crystalline cells connected to a single electrical inlet and output in one end of the strip; and that the strip at the same time is having a facing layer of rigid transparent tiles in the scale of a pitched tiled roof spaced from each other to provide sufficient gaps to allow the finished strip to be bent, rolled or folded; and that such strip should be laminated in one sin gie step.

SUMMARY OF THE INVENTION

Present invention contemplates novel material configurations and methods of manufacturing and installation of building-integrated systems that remedy some of the disadvantages of prior art. Present invention may however also be used in other product areas such as cladding of facades, vehicle-integrated photovoltaics, solar power plant structures and paving/road construction systems .

Basically, the device central to the present invention is comprised of a strip of pre-wired solar circuits on a substrate of a waterproof flexible membrane that may be a roofing membrane cut from a continuous roll before or after the cell circuit is formed thereon.

In one embodiment, a first film of encapsulating material is laid down on the substrate and pre-wired strings of preferably crystalline cells are laid down on said film and connected to a single in- and outlet forming a single electric circuit.

A second encapsulant film is placed over the circuit and a transparent plastic foil e.g ethylene tetrafluoroethylene (ETFE) is uncoiled from a continuous roll and laid down onto said second encapsulant covering the entire circuit.

Then one or more sheets of a third encapsulant film is placed over said transparent foil and individual rigid transparent sheets are then positioned over said encapsulant to cover one or more photovoltaic cells. Preferably said sheets have the scale of a tiled roof characterized by relatively short distance between gaps, by varying gap widths and by offset gaps. Hereon forth rigid transparent sheets are called tiles.

In one embodiment, the layering onto the substrate will start with an extra layer of encapsulant film on which an opaque plastic foil is positioned. In another embodiment, the assembly will start with a layer of rigid backing sheets and an extra layer of adhesive on to which the substrate is laid.

Preferably, the assembled components are then treated in one lamination step by applying vacuum, heat and pressure thereto to remove air from the assembly, then melt and cure the encapsulant films and finally press the assembly to a laminate thereby bonding the circuit to the substrate, the transparent foil to the circuit and the rigid transparent tiles to said foil.

Accordingly, present invention proposes a novel configuration effectively providing electrical insulation of the circuit of cells under the gaps between the tiles positioned on top of said circuit during shipment, installation and operation.

The advantages of present invention are many. First ly, a multitude of gaps with various widths on top of the circuit allow for even very long e.g. 5 meter single circuits to be bent, rolled or folded for efficient shipping, handling and installation. Secondly a very long solar strip connected to a single electrical inand outlet and thus avoiding multiple junction boxes in the middle of the strip can save amounts of time in fabrication and installation. Thirdly, the relatively small area of the tiles in combination with an additional cushioning resulting from an extra layer of encapsulant enhances the systems impact resistance providing for thinner, lighter and less costly tiles, especially for tiles made of glass. Additional advantages will be recognized from the following descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Figures 1-4 show cross-sections and layouts of the invention. Orientation, scale and proportions are solely selected for presentation reasons. In the following the invention is explained more in detail with reference to the drawing, in which

- figure 1 shows a cross-sectional view of a strip, taken along line 1-1 where layers are separated for the sake of clarity,

- figure 2 shows a top view, partly broken, of an in tegrated solar cladding strip,

- figure 3 shows a cross-sectional view of said strip, taken along line 3-3 where layers are separated for the sake of clarity,

- figure 4 shows the principles of the sixth aspect installed on a building part,

- figure 5 shows the principles of installing strips with angle cut ends, and

- figure 6 shows an axonometric view of a strip that is bent and folded, and

- figure 7 shows another axonometric view of a strip that is folded with headlaps.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to figure 1 illustrating an embodiment of the invention where the substrate (2) is a roofing membrane comprising synthetic and/or bituminous (tar/asphalt) products. While current invention preferably uses hot-melt adhesives as encapsulant most bituminous membranes would unfortunately not fit these adhesives ' temperatures and curing times why cold curing encapsulants such as silicone may be used as an alternative. Consequently, any sheet of material used to cover a flat or low-pitched roof, usually known as a membrane or film may be considered as substrate (2).

In a preferred embodiment, a waterproof synthetic membrane is uncoiled, such as a membrane made of single or multi-ply polyvinyl chloride (PVC), polyvinyl fluoride (PVF), ethylene vinyl acetate (EVA), thermoplastic polyolefin (TPO), filled polyolefin (FPO) or Ethylene Propylene Diene Monomer (EPDM) often in combination with plasticisers such as phthalates or EVA, and with additives such as UV- and flame retardant and with or without a reinforcing material. The most common thickness is 1,5 mm but both thicker sheets and thinner films may be used. A non-woven fleece may also cover the backside of the substrate.

A first film of encapsulating material (3) is uncoiled and laid down on the substrate. The film may be cut from a continuous roll before or after the cell circuit is formed thereon. The term encapsulant means a encapsulating adhesive providing insulating, cushioning and structural support to solar cells and circuitry, while maximizing transmission of sunlight. Encapsulant bonding is suitable for both flexible and rigid areas with excellent adhesion to all photovoltaic components. The preferred encapsulant in present invention is ethylene-vinyl acetate (EVA) having outstanding adhering and weathering properties that protects the cladding material throughout its lifecycle of approximately 25 years. The EVA base is normally combined with a number of additives in the foil extrusion process, including curing agents, UV stabilizers, anti-oxidants, and primers for glass adhesion. EVA's melting point when it turns to a gel is typically about 70°C and the curing temperature and time is typically 145°C in 20—25 min. Other encapsulant bonding materials may also be used such as thermoplastic polyurethane (TPU) or polyvinyl butyral (PVB). In one embodiment, the layering onto the substrate will start with an extra layer of encapsulant film (not shown) on which an opaque plastic foil (not shown) is positioned.

Conventional crystalline silicon solar cells (c-Si) have electrical contacts made from busbar contacts and fingers printed on the front of the wafer, but back contact cells may also be used. Preferably c-Si cells (5) are placed in an equipment called a stringer performing the operation of stringing meaning interconnection of c-Si cells in series by soldering a coated copper wire, called a tab-wire (6) on the single or multiple, front or back, bus bars of the c-Si cell (5). This stringing operation, is often performed by weaving a tab-wire (6) from electrical contacts on the front on one cell to the back on an adjacent cell, bridging the gap between cells thereby creating the string of cells in electrical series having wired spaces with fixed or with alternating lengths.

In figure 2, the arrows 1-1 and 3-3 refer to the cross-sectional view of figure 1 and 3. Furthermore figure 2 is showing how one or more pre-wired strings (7) of crystalline cells (5) are laid down on said first encapsulant film (not shown). Ribbon-wires (8a, 8b) are also laid out and connected by soldering to a single inand outlet forming a single electric circuit (4) where the long sides (L₄) are at least one and a half times longer than the short sides (S₄).

Referring again to figure 1, a second encapsulant film (11) is uncoiled, potentially cut, and placed over the circuit.

Then, a transparent plastic foil (12) is uncoiled from a continuous roll and laid down onto said second encapsulant covering the entire circuit. Several polymeric products for solar laminates are currently on the market. In a preferred embodiment the transparent protecting foil is a transparent fluopolymer with good resistance to vapour permeation such as ethylene tetrafluoroethylene (ETFE) which is a fluorine-based plastic, but the foil may also be of other more elastic transparent plastics such as polyethylene terephthalate (PET), fluorinated ethylene propylene (FEP), perfluoroethers (PFA) or polymide (PI). Frontsheet foils come in different thicknesses most commonly 50-100jum but thicker or thinner may also be used. DuPont™ Teflon®, Saint-Gobain Lightswitch™ and AGC Fluon® frontsheet films are exam pies of such product brands. These products are designed for high resistance and strength over a wide range of temperatures. One or both surfaces may be treated with etching or so-called corona treatment for enhanced adhesion properties.

Then, one or more sheets of a third encapsulant film (13) are placed over said transparent foil. For practical reasons a coherent layer of encapsulant on both sides of a transparent protective foil is preferred, but alternatively a multitude of cut sheets of the third encapsulant film (13) may be laid out leaving the gaps without encapsulant material. Preferably however, a single sheet is uncoiled and laid out to cover the entire area of the transparent plastic foil (12), potentially with the exception of coherent areas such as the area under the junction box (20). This procedure, resulting in exposed encapsulant on the bottom of at least narrow gaps, provides some advantages. Firstly, a cost effective lay out operation and secondly the possibility of adhering granule materials (21) to the gap in the laminating process. Thirdly, a positive side effect with sprinkling a granule over the gaps is that it also prevents encapsulant to stick to the upper membrane of the laminator. Material such as crushed stone such as shale or slate, or brick are common on roofs and facades and have a distinct decorative quality. Additionally, gaps between juxtaposed tiles may also be filled with a water setting or a one- or a two-component grout or sealant after installation.

Individual flat tiles (14) are then positioned over said encapsulant to cover one or more photovoltaic cells. Optionally tiles may be non-flat having one or more bent edges (30). Current invention's tile is preferably made of tempered glass with a thickness of 2 mm, but material, thickness and reinforcement of a tile is ultimately a result of load and impact performance requirements in standards such as IEC 61215:2005.

Preferably tiles (14) have the scale of a tiled roof characterized by relatively short distance between flexible gaps (15), by varying gap widths and/or by offset gaps. A tiled area (33) may have two types of margins; protruding margins (16) serving as flashings overlapping protruding cladding, and in-circuit margins. The latter containing laminated wires electrically connecting one or more strings inside the circuit, heron forth considered as a gap and termed margin gap (15'').

Protruding margins (16) may have additional memory layers (40) as well as preferably butyl based sealing strips (41) and may be tab-shaped in order to be readily folded over an adjoining or supporting structure. Memory layers (40) remembering a shaped geometry of the margin, are preferably adhered by the first (3), and potentially the second encapsulant film (11) in the assembly operation, but may also be adhered after lamination. Memory layers (40) are preferably made of a metal such as aluminum in the shape of a sheet, perforated sheet, expanded sheet or having a knitted, woven or honeycomb structure that potentially may be creped, crinkled, corrugated or elsewise profiled in a finishing operation.

If tiles are made of glass they may be patterned permitting easy lamination as well as coated for nonblinding or decorative effects, standard or low-iron glass (FeO < 5%) may be used resulting in different insolation. Textured, tinted, micro-structured, iridescent tiles may be used as well as tiles perforated with drilled holes (figure 7). When it comes to tile sizes most pitched roof tiles have sides measuring between 20 and 40 cm. Tile sizes should take into consideration the measurements of common rigid c-Si cells as well as standard sizes of marketed roof tiles. Cells made of multi-crystalline and mono-crystalline silicon are normally measuring 5'' or 6 '' (125 or 156 mm) in square but may be cut in smaller rectangles or squares.

Again, referring to figure 2 and 3, the gaps may be lined up in one or more transverse rows of gaps (15'). The width of the rows in combination with the radius (22) of the tile's edge and the thickness of the tile, have practical implications on the flexibility of the gaps. Larger gap width or edge radius will ease the bending and even admit rolling or folding which may be practical in transporting and handling the strip (1) as well as in the installation on the construction site. Consequently, different gap width requirements may be conceived in order to allow for the flexible gap to fulfill different options of functionality. For example, but not exclusively, a gap width that allows the cladding strip in itself to become rolled into a coil and/or to become, preferably using a gap width of 3-30mm, folded into a fan-fold or saw-tooth shaped configuration, preferably using a gap width of 30-300mm. Glass tiles' radius (22) of very small tiles may be polished but are most efficiently created through baking of raw cut tiles. After baking the tiles may be placed in a mold with the joint width distance, and netted on the top surface with a removable net in sheets of for example 4x5 tiles ready to be laid up for lamination.

The assembly of layered materials is then cut. The term cutting means all kinds of operations separating pieces of material including the operations of chopping and slitting with some kind of cutting tool including a knife, saw, water-jet cutter, laser cutter, air-jet cutter, plasma cutter, guillotine cutter etc.

In order to create an electrical circuit (4), the assembly operation proceeds with the soldering of wires: the plated tab-wires (6) to terminal ribbon-wires (8c) and transverse ribbon-wires (8b) that potentially are soldered to one or more alongside ribbon-wires (8a). The generic term for all electric wiring is hereon forth just wires. A ribbon-wire (8a, 8b, 8c) is a plated copper wire, normally of larger thickness than the tabwire (6), that is used for interconnecting the strings. Tab-wires may be connected to bus bars on the front of the cell or to back contacts. In many photovoltaic production lines, the soldering and out-bringing of terminal ribbon-wires (8c) ending in the junction box (20) through a cut in the substrate (2) or the transparent protecting foil (12), is performed manually. The multitude of flexible gaps (15,15 ',15 ' ' ) on top of the circuit allow for a very long e.g. 5 meter single circuits to be bent, rolled or folded for efficient shipping, handling and installation. The advantage of a very long single circuit laminated into a strip (1) is that the installers can save substantial amounts of time and money connecting each strip (1) with a single inlet and output of electricity (20).

Vacuum laminating of the assembly is preferably performed with a double-chamber laminator using belt-fed loading of the lower vacuum chamber on top of a very long heated metal plate, potentially up to 6 meters. But membrane-less laminators, multiple parallel laminators, stack laminators, multi-stage laminators or continuous double belt press laminators may also be used. The laminator's cover comprises an upper vacuum chamber that opens for loading and unloading modules. The lamination process normally involves pumping the air out of the assembly in a vacuum chamber, heating the layers to melt the encapsulant, and pressing the assembly together preferably with a flexible diaphragm to embed the cells in encapsulant and adhere the layers of the assembly. A flexible diaphragm is attached to the bottom of the upper vacuum chamber, and a set of valves allows the chamber above the diaphragm to be evacuated during the initial pump step and backfilled with room air during the press step. A pin lift mechanism is sometimes used to lift the laminate above the heated metal plate during the initial pump step.

After lamination, the strip (1) may be trimmed, slit and finished including application of the junction box. Application is typically done by attaching the box with a suitable silicone or glue on to the front of the transparent protecting foil (12) or on to back of substrate and electrically connecting terminal ribbon-wires (8c) in the junction box (20) and cables (23). At the inside of a box by-pass diodes as well as a micro inverter may be installed, protecting the solar membrane when operating. Flat by-pass diodes may also be installed in the laminate connected in parallel with single c-Si cells. Diodes are installed to prevent cell overheating and allowing the PV modules to produce power even when partially shaded or soiled. Since diodes produce heat they are normally installed in a junction box since the energy loss in diodes tends to result in designs with as many c-Si cells per diode as possible within the standard (normally 25 cells). Finally, at the end of the assembly the PV module is being controlled, tested and classified where the electrical output is labelled according to the chosen classification. The tiled solar membrane is thus obtained and ready to be commercialized and installed.

Optionally the backside of the strip may be partially covered with additional layers such as rigid backing sheets or adhesive coatings and/or thermal collectors. Rigid backing sheets or tiles may be added in the assembly operation to improve mechanical protection of the cells. Adhesive coating layers, potentially including a release foils, and/or thermal collectors are optionally added after lamination. The additional layers of a thermal collector may include conductive adhesives and insulation. The thermal collector may be a component in a hybrid PV/T system (PVT) collecting thermal energy while heating a working fluid in order to cool down the cells and transfer the energy at a heat exchanger increasing the yield of the module. A PVT may also generate heat energy for residential use while connected to a heat accumulation tank and/or a heat pump for home heating.

Normally roofing membranes and other claddings are adhered, screwed, nailed, stapled, clamped or otherwise secured to the roof (e.g. sheathing, roofing underlay, sarking, insulation, roof battens etc. or to an existing roof). But fixing by means of ballast, vacuum or hook and loop fasteners may also be used. Profiles, decorative details and fittings may also be fixed, adhered or welded to the strip for functional or decorative purposes .

Referring to figure 3, the area of the laminated substrate layer (2) is divided into a circuit area (4) including one or more protruding margins (16) outside the circuit. The membrane may also have additional flashings (24) fixed to the back of the membrane creating pockets (25) sealing a seam of two overlapping strips. This is normally made by means of hot air welding where the overlapping surfaces are melted whereafter the top layer is pressed onto the lower with a wheel. Companies such as Leister are specialized in hot-air welding technology such as automatic welders and hot-air hand tools.

Referring to figure 4, showing how a strip edge (26) is folded up and away from the seam making space for the hook-shaped mouthpiece of an automatic hot-air welder to reach the overlapping lips of flashing (24) and protruding margin (16) welding them in lines giving the building part a coherent, even and decorative surface when strip edge (26) is folded back and secured.

Referring to figure 5, showing the plan of a roof with an array of membrane strips. Some strips being integrated solar cladding strips (1) and others being a combination of membrane strips complemented with ordinary laid tiling. The strips (1) may have one or two angle cut ends (27) hereby allowing for square diamond oriented tiles. A single strip of the invention can only produce a limited amount of power. Therefore most installations will contain multiple strips, interconnection wiring, one or more solar inverters and sometimes a battery in a complete solar installation. Electrical connections are made in series to achieve a desired output voltage and may use designated weatherproof connectors to the invention's junction box. The strip's junction box may be concealed behind roof battens but sometimes one may want to avoid a junction box in the middle of the roof. Then it may be concealed behind a soffit, preferably attached to the back of the strip and recessed in the underlay sheeting of the eave. If hidden under the flashing cap of a ridge, it's preferably attached to the front of the strip.

Referring to figure 6, showing an axonometric view of a cladding strip (1) where a single circuit comprise a plurality of tiles (14) (rendered gray for the sake of clarity) with transverse rows of gaps (15'), margin gaps (15'') and protruding margins (16). When tab-wires (6) are withdrawn from a part of the gaps (15') area, this area may be slit (34) as shown along the dashed lines. A protruding margin (16) is shown folded, keeping its shape due to memory layers as described in figure 1. Margins may for example be folded over a supporting structure such as a roof tile.

Referring to figure 7, showing an axonometric view of a strip (1) which is folded. The single electric circuit (4) comprise a plurality of tiled areas where tiles (14) are rendered gray having narrow gaps (15), wide transverse rows of gaps (15') and margin gaps (15''). Gap areas may be processed with slits (34) and folds (35) creating a cladding structure with headlaps (36). The figure also shows a junction box (20) adhered to the back as well as fixing arrangements comprising installation hooks (37), battens (38) and tile holes (39) for fasteners .

In a first aspect according to the present invention it is provided an integrated solar cladding strip wherein the hot-melt adhesive encapsulants are substantially made of ethylene vinyl acetates (EVA) or thermoplastic polyurethane (TPU) or polyvinyl butyral (PVB) with excellent adhering, cushioning properties and a transparent protecting foil substantially made of ethylene tetDK 179442 B1 rafluoroethylene (ETFE) or polyethylene terephthalate (PET) or Polyvinyl chloride (PVC) with excellent weathering properties hereby protecting the electric circuit throughout its lifecycle of approximately 25 years.

In a second aspect, it is provided an integrated solar cladding strip with a single circuit area formed as a long rectangle potentially with return ribbon-wires running alongside the strip returning one or more stings to a single junction box hereby avoiding multiple junction boxes in the middle of the strip.

In a third aspect, it is formed as a strip with sufficient gaps width giving it flexibility to be rolled into a coil or folded into a fan-fold hereby allowing for effective transport, handling and installation on the construction site.

In a fifth aspect, the transparent protecting foil is entirely encapsulated on both sides with hotmelt adhesive encapsulant hereby adhering a facing layer of sand, granules or tape in the gaps.

In a sixth aspect, it is provided a strip having protruding margins or fixed flashings and that the flashings have pockets allowing strips to be folded up giving room for an automatic hot-air welder to reach the over lapping lips welding the seam in lines giving the building part a waterproof surface.

In a seventh aspect, it is provided a strip having non-flat tile with one or more bent edges hereby allowing it to be installed side-by-side with non-flat roof tiles.

In an eighth aspect, it is provided a strip having a thermal collector attached to the back of the substrate after lamination hereby allowing it to be installed as a hybrid PV/T system (PVT).

In a tenth aspect, it is provided rigid backing sheets adhered to the back of the substrate hereby improving mechanical protection of the cells.

In an eleventh aspect, it is provided a substrate being a commercial roofing membrane, hereby using standard certifications, tools and installation procedures.

Claims

REQUIREMENTS

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A solar cladding web (1) comprising:

a substrate material (2) consisting of a waterproof flexible roof membrane, a first layer of an adhesive hot-melt encapsulant (3), a single electrical circuit (4) comprising solar cells (5) whose positive and negative sides are interconnected by a loss line (6) to form one or more strands (7) which are connected to a ribbon wire (8) which is connected to a single electrical inlet (9) and a single outlet (10), a second layer of adhesive hot-melt encapsulating means (11), a single sheet of a transparent plastic foil (12) covering and protecting the whole circuit (4) from moisture, a third layer of adhesive hot-melt encapsulating means (13) and a plurality of rigid transparent tiles (14) characterized by the tiles (14) are placed over one or more cells (5) forming rigid groups separated from each other by flexible spaces (15, 15 ') which are positioned over loss lines (6) which run between the cells (5).

A solar cell cladding web (1) according to claim 1, wherein the tiles (14) are made of glass.

A solar cell cladding web (1) according to claims 1-2, wherein the first (3), second (11) and third (13) layers of adhesive hot-melt encapsulant are mainly made of ethylene vinyl acetates (EVA) or thermoplastic polyurethane (TPU). ) or polyvinyl butyral (PVB).

A solar cell cladding web (1) according to claims 1-3, wherein the transparent plastic foil (12) has a thickness of 0.04-0.15 mm and is mainly made of polytetrafluoroethylene (ETFE) or polyethylene terephthalate (PET) or polyvinyl chloride (PVC). ).

A solar cladding path (1) according to claims 1-4, wherein the circuit (4) area is rectangular in shape where the long sides (L ₄ ) are at least one and a half times longer than the short sides (S ₄ ).

A solar cell cladding web (1) according to claims 1-5, wherein flexible spaces (15) are lined up in one or more rows (15 ') which have enough width for the web (1) to be able to be rolled or folded.

A solar cell cladding web (1) according to claims 1-6, wherein one or more ribbon wires (8) run along the direction of the web (1) and return one or more strands (7) to a junction box (18) for electrical intake ( 9) and outlets (10).

A solar cell liner web (1) according to claims 1-4, wherein the transparent plastic foil (12) is completely encapsulated on both sides of the second (11) and the third (13) layer of adhesive hot-melt encapsulant.

A solar cell cladding web (1) according to claims 1-4 and 8, wherein the surface in the spaces (15, 15 ') is sand, granulate or a tape.

An assembly operation for manufacturing a solar cell cladding web (1) according to claim 1, wherein at least the following steps are included;

rolling out a substrate material (2),

rolling out a first film of encapsulant (3),

stringing and laying one or more strands (7) of crystalline cells (5),

- laying of ribbon wires (8a, 8b),

- rolling out the second film of encapsulant (11),

- rolling out the transparent plastic foil (12),

- rolling out the third film of encapsulant (13),

- laying a plurality of tiles (14),

- cutting of the rolled-out materials,

5 - soldering of ribbon wires (8) and application of terminal ribbon wires through the substrate (2) or through the transparent plastic foil (12),

- vacuum lamination of the assembled materials,

- trimming and finishing of solar panels

10 lanes (1).

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