Prototype design and development of low-load-roof photovoltaic modules for applications in on-grid systems

Abstract

Four prototypes of lightweight photovoltaic modules for applications in on-grid systems have been designed, developed, manufactured and tested for compliance with relevant IEC standards. Selected, commercially available materials characterized by thermogravimetry, differential scanning calorimetry, dilatometry, scanning electron microscopy and nanoindentation technique were used in frameless, adhesively-bonded sandwich-structures carrying the interdigitated back contact solar cells. With dedicated manufacturing processes the prototype-dependent weight between 3.37 and 3.77 kg/m 2 , the STC-maximum power in the range of 221–239 Wp together with power conversion efficiencies of 19.98–20.71% were obtained. Millimetre-sized texture improved module's performance for steeper solar incidence angles. The self-cleaning capability of modules was enhanced by a hydrophobic material utilized in front linings. The structure of the prototypes helps to build non-intrusive installations on low-load capacity roofs, even in large-scale lightweight buildings. • Four prototypes of lightweight photovoltaic modules were designed and developed. • Thermal and mechanical parameters of base materials were determined. • The results of the prototypes' complete IEC test sequence were presented. • Construction details and manufacturing processes were described.