Design of Post-Consumer Modification of Standard Solar Modules to Form Large-Area Building-Integrated Photovoltaic Roof Slates

Abstract

Building-integrated photovoltaic (BIPV) systems have improved aesthetics but generally cost far more than conventional PV systems because of small manufacturing scale. Thus, in the short and medium term, there is a need for a BIPV mounting system that utilizes conventional modules. Such a design is provided here with a novel modification of conventional photovoltaic (PV) modules to allow them to act as BIPV roofing slates. The open-source designs for the mechanical components necessary to provide the post-consumer conversion for a conventional PV module are provided, and prototypes are fabricated and installed on a mock roof system along with control modules mounted conventionally. The approximately U.S.$22/module BIPV roof-mounted system is direct mounted on the roof to eliminate the need for roofing shingles or other coverings, which effectively provides a 20% total cost reduction from conventional racking systems that demand a roof to mount upon without considering the savings from the rack itself. The results of the outdoor system testing found no water leaks. An increased operating temperature was observed, which would reduce the output from a silicon-based PV module by less than 10%. The results found significant potential for this design to further reduce total PV systems costs.

Prototyping Roof Mounts for Photovoltaic (PV) Panels: Design, Construction and CFD Validation

“…To perform a comparison with the design presented in ref. [20] the batten we present has a shorter length, of 600 mm as shown in Figure 4 (a), and is constructed with curved edges of radius 2 mm as shown in Figure 4 (b), to reduce vortices in air-flow past the structure. The link channel, as shown in Figure 3 (a), is then screwed on top of the batten, allowing a space to let the water slide over the Butynol mat so that the water remains uncontaminated.…”

“…Based on ref. [20], it is recommended to add an aluminum channel, as flashing to prevent water ingress at the head of the BIPV roofing system. The advantages of our design is that the batten is not undermined by high wind speeds, uses natural ventilation to prevent moisture build-up, and maintains potability of rainwater so can be used in conjunction with rainwater collection systems.…”

“…Their study focuses on quantifying water intrusion during the severe conditions, and they noted that this was significantly affected by the amount of rubber sealing applied, and the potential for deformation of the seals during installation. Also, Pearce et al, [20] presented a modification based on an open-source design in which conventional PV modules were converted to BIPV roofing slates via direct mounting, which achieved a 20% total cost reduction.…”

“…Previous studies [23,24] shed light on specific solutions for the identified issues. Additionally, certain cuttingedge technologies such as the novel kesterite technology [25,26] and conversion of commercial ceramic tiles for BIPV [20,24] purposes are also identified, which require further research. In the past, the design of the PV panels themselves have received significant attention [27]; however, the design and analysis of panels' mounting unit [28] have not received much attention.…”

Review on Building-Integrated Photovoltaics Electrical System Requirements and Module-Integrated Converter Recommendations

“…A wide variety of BIPV modules is commercially available on the market [3,[36][37][38][39]. In general, two classes of BIPV modules are distinguished, namely roofing BIPV modules [40] and façade BIPV modules [3,41]. The first category consists of PV modules that are part of the roof structure of a building, comprising in-roof systems, full roof solutions, and solar tiles.…”