PV Module Prototypes for Integrated Photovoltaic Systems

Integrated Photovoltaics, from building-integrated photovoltaics (BIPV) to urban photovoltaics (UPV), offers many opportunities to use the same surface for several purposes: for energy generation, but also as a house roof, pedestrian path or vehicle shell, for example. (Link to the integrated PV website). The applications result in additional requirements for the module technology. A specially adapted module technology is often required for the respective application. In addition, the mechanical and electrical integration of the module into the overall system must also be considered and solutions must be found that offer homogeneous and optically high-quality integration with low electrical losses.

We develop modules and module products for integrated photovoltaics, tailored to the respective application of our customers and partners. To this end, we find and enable innovative solutions that are optimized to meet the requirements in terms of solar yield, manufacturing costs, durability and regulatory requirements for the system and also represent an aesthetically high-quality integration. 

As part of our R&D activities, we offer our customers the following services: 

• Development of interconnection technologies
• Optimization of manufacturing processes on industrial systems
• In-house test days to evaluate materials and processes
• Development of aesthetic and lightweight modules
• Testing of modules in accredited laboratories in preparation for certification
• Evaluation of the modules in terms of cost-effectiveness and manufacturability

Our R&D-Activities on the Topic "PV Module Prototypes for Integrated Photovoltaic Systems" Include:

• Module Design and Layout Creation
• Prototype Construction with Various Cell and Material Technologies
• Building-Integrated Photovoltaics (BIPV)
• Vehicle-Integrated Photovoltaics (VIPV)
• Photovoltaics in Traffic Routes (RIPV)

Solar modules in integrated photovoltaics often not only have the task of generating electricity, but also offer additional benefits for users. In order to fulfill these additional functions and still reliably supply electricity in the long term, the design must be specially adapted. The basic structure of the module, the integration and installation in the respective applications and the electrical design of the system must be taken into account. Based on the applications, we develop special module designs, interconnection concepts and electrical layouts as well as system concepts. 

Our Services

• Development of module designs optimized for the respective application 
• Development of mechanical interconnection concepts and module layouts
• Creation of module layouts to optimize the electrical yield 
• Development of system concepts for optimized electrical interconnection of the modules

Based on designs, we develop and build initial prototypes in order to carry out durability tests or equip convincing demonstrators. We have access to an incomparably wide range of cell and material technology in order to produce optimized modules for the corresponding applications. We can not only produce hand samples and small samples in our facilities, where the processes are based on those of series production, but also initial semi-finished products, full samples and prototypes. Based on this, we evaluate the various development steps. In our Module-TEC, we produce PV modules for small series or for equipping demonstrator surfaces. For large-scale production, we transfer our expertise from development to module manufacturers. 

Our Services

• Use of various solar cell technologies (c-Si, tandem, thin-film) and various material groups (glass, films, metal, fiber materials) possible 
• Production of small-format test samples and prototypes for initial testing purposes and as hand samples 
  
• Production of full-size modules for durability tests 
  
• Small series production and production of modules for demonstrator equipment 
  

In Building-Integrated Photovoltaics (BIPV), modules are used as construction elements to take over functions of the building envelope, such as thermal insulation, wind and weather protection as well as architectural functions. We develop and optimize module structures as cost-effective and durable module systems on facades. Our focus is on module technology, in which a wide variety of cell technologies and material systems can be used, depending on customer requirements. Samples can be produced in our Module-TEC from small module sizes to the equipment of demonstration objects on industrial plants. 

Our Services

• Development of innovative and aesthetic interconnection concepts for cells and modules 
• Novel encapsulation materials for improved integration of solar modules into façade elements 
• Production of BIPV prototypes with variable cell and module formats, designs and materials 
• Support in the design and planning of BIPV systems (potential analysis, building law aspects, evaluation of visual effects) 
• Optimization of the thermal, visual and electrical properties of building envelope components

In Vehicle-Integrated Photovoltaics (VIPV), specially adapted modules are required: they need to adapt to the vehicle shell, be particularly light yet robust and meet the requirements of the vehicle design. Based on the wide range of cell technologies, material classes and the various processes for manufacturing prototypes, we develop module samples and their electrical and mechanical integration into the vehicle. We can produce and test demo samples for passenger and commercial vehicles in various formats and all curvatures. 

Our Services

• PV technology consulting 
• Design and development of prototypes for integrated PV 
• Determination of the solar energy yield for regions, routes or tracks 
• Module tests for reliability 
  
• Vehicle electrical system integration (drive train of electric vehicles, auxiliary units) 
• Energy and load management, power electronics and battery systems 
• Power yield and cost analysis 
• Coordination and management of R&D projects with industry partners 

When integrating solar modules into traffic infrastructure systems (RIPV), there are different approaches, each of which requires different module technologies. When used for roofing, the modules must be designed for special safety requirements; when integrated into noise barriers, noise absorption is also required; and when integrated into paths and rail surfaces, solar modules must replace the function of the path surface. We develop solutions and concepts that are cost-effective to manufacture, easy to integrate and durable. 

Our Services

• PV technology consulting and cost optimization 
• Design and development of prototypes  
• Determination of the solar energy yield  
• Module reliability tests 
• Power yield and cost analysis 
• Coordination and management of  
• R&D projects with industrial partners