ITMI20130483A1 - INTEGRATED PHOTOVOLTAIC SYSTEM AND ITS IMPLEMENTATION METHOD - Google Patents

Description

DESCRIPTION

â € œ INTEGRATED PHOTOVOLTAIC SYSTEM AND RELATIVE METHOD OF

REALIZATIONâ €

FIELD OF APPLICATION

The present invention relates to an integrated photovoltaic system. The present invention furthermore relates to a method of manufacturing the aforementioned integrated photovoltaic system.

TECHNIQUE NOTE

The building envelope is nothing but the presentation and contact surface that connects the building with the outside world.

It is a sort of "business card" with which the building offers itself to the surrounding environment. Over the centuries the appearance of the buildings has changed profoundly and from time to time reflecting the socio-cultural climate of which it was in some way the architectural reflection.

Today much more attention is paid than in the past to the balance between aesthetic and functional factors.

The energy issue is the one that most affects the design of the building envelope, and also influences the requirements and performances to which modern envelopes must meet. A particular role in this regard is played by the integration offered by the casings with respect to the technologies of passive and active exploitation of solar radiation.

From the concept of envelope as an energetically passive element, of separation between internal and external environment, we move on to the concept of envelope as a dynamic and interactive element of the complex energy system that regulates the functioning of the building and characterizes its image.

The technological evolution of the energy performance of the architectural envelope is adjustable and perceptible through the dematerialization of the surfaces that constitute it.

The massive opaque elements of vertical and horizontal closure are pierced by transparent surfaces of ever greater dimensions, which in recent times have replaced and constitute the entire architectural delimitation element.

The increasingly frequent use of transparent surfaces for the construction of buildings involves the development and research of new materials capable of guaranteeing energy performance similar to the traditional materials with which buildings have been built for centuries.

The envelope is released from the load-bearing structure of the building and becomes a closing element called to regulate mainly the energy flows linked to the passage of heat, to the transmission of light for adequate lighting of the internal environments and to the protection of solar radiation in the months with the highest temperatures.

The technological solutions and the choice of materials are oriented towards those systems that are able to manage these thermal and light exchanges, while guaranteeing the aesthetic requirements dictated by the new architectural languages.

In many contemporary buildings the envelope is made with facade systems that allow the accumulation of incident solar energy and transform it into heat to accumulate the building's winter energy needs, in others the envelope becomes a real and its own active element of energy production, thanks to the integration of technological systems linked to renewable energy sources (photovoltaic and solar thermal).

The opaque and transparent vertical closures are developed as complex technological components capable of interacting with the surrounding environmental conditions, capable of reducing the energy needs of the building.

The use of integrated photovoltaics in architecture means being able to balance the technical and aesthetic aspects of the components of photovoltaic technology with those of the building envelope, without compromising the functional characteristics of both.

By combining the use of photovoltaic integrated into the building envelope, capable of powering a control system between the outside and inside, and the energy systems of the building itself, the goal is greater comfort and the reduction of the energy needs of the building itself.

With current techniques, the assembly of photovoltaic glass takes place directly on site on the facade of the building.

It is necessary to work in tandem of the teams of fitters and electricians who, working sequentially, assemble the glasses on the structure and carry out the wiring and interconnections.

There are numerous drawbacks deriving from this type of configuration:

â € ¢ It is not possible to build prefabricated modules, as everything has to be assembled on site;

â € ¢ teams of electricians must follow the work of the installers sequentially;

â € ¢ the employment time of skilled labor on site is not compressible;

â € ¢ the connection cannot be easily integrated into the structure and remains visible;

â € ¢ Good aesthetic integration is not easily obtainable.

In the light of all the disadvantages shown, it is therefore an object of the present invention to provide an integrated photovoltaic system and related construction method that guarantees greater comfort and a reduction in the energy requirement of the building itself.

In particular, the specific aim of the present invention is to provide an integrated photovoltaic system and related manufacturing method which guarantees easy assembly by overcoming the drawbacks of the known art.

SUMMARY OF THE INVENTION

These and other purposes are achieved by an integrated photovoltaic system according to what is described in the attached claims 1 to 9.

These and other purposes are also achieved by a method of manufacturing an integrated photovoltaic system according to what is described in claim 10.

The invention achieves the following advantages:

â € ¢ proposes a new integration standard that takes the place of the few ad hoc solutions now on the market, surpassing them in terms of economy, performance and ease of installation.

â € ¢ The reliability of this type of products also increases, because the integrated solution is equipped with continuous monitoring systems for control and diagnosis in real time.

â € ¢ The solution lends itself, in fact, to open new frontiers in the renewables market and sets, as its primary objective, the change of the construction philosophy from purely passive to active architecture, useful for the environment, clean.

â € ¢ simplicity of installation, which, thanks to a project focused on a â € œplug and playâ € electrical connection system, makes it easier to install photovoltaic glass, minimizing the installation phases on site.

â € ¢ construction of the facade of a building by pre-assembling the islands of photovoltaic modules in the factory which can then be interconnected on site, simply by mounting the islands and connecting them using the already integrated wiring, guaranteeing an advantage over the current state of the art , where the modules are mounted on site on the facade and then the teams of electricians carry out the wiring and interconnections, with all the related problems.

The cited technical effects and other technical effects of the invention will result in more detail from the description, given below, of an example of embodiment given by way of indication and not of limitation with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figures 1a, 1b and 1c show a first component of the integrated system of the invention according to different views.

Figure 2 shows a second component of the integrated system of the invention.

Figure 3 shows an overall view of the first and second components of Figures 1 and 2.

Figure 4 shows the system of the invention assembled and ready for use.

Figure 5 is an exploded view of the system of the invention shown in Figure 4.

Figure 6 is a detail view of the system shown in Figures 4 and 5, according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention describes an integrated photovoltaic system comprising a modular support frame, a plurality of photovoltaic glasses mounted on this frame, a connection apparatus, for a connection between the plurality of photovoltaic glasses and the support frame, in which the The connection apparatus comprises a connection base adapted to be connected to the photovoltaic glass and a junction box removably associated with the connection base and adapted to be electrically connected to the support frame.

With particular reference to figures 4,5 and 6, the integrated photovoltaic system of the invention comprises a modular support frame 3. Preferably, this frame 3 comprises an island structure.

According to the invention, the modular support frame 3 comprises at least a first through cavity 31 (fig. 5 and 6).

Preferably, the first through cavity 31 is obtained in a substantially peripheral position of the support frame 3.

The integrated photovoltaic system of the invention further comprises a plurality of photovoltaic glasses 2 mounted on the support frame 3.

Advantageously, according to the invention, at least one of the photovoltaic glasses 2 comprises a second cavity 21.

The second cavity 21 occupies a thickness of the photovoltaic glass lower than the total thickness of the glass itself; in other words, it is a non-passing or blind cavity.

The second cavity 21 is positioned in a substantially perimeter area of the photovoltaic glass 2.

The system of the invention also comprises a connection apparatus 1, for a connection between the plurality of photovoltaic glasses 2 and the support frame 3.

According to the invention, the connection apparatus 1 is at least partially housed in the first through cavity 31.

According to the invention, the apparatus 1 comprises a connection base 10 suitable for being connected to the photovoltaic glass 2 and a junction box 11, removably associated with the connection base 10, and suitable for being electrically connected to the support frame 3.

The connection base 10 and the junction box 11 determine an electromechanical connection interface between the photovoltaic glass 2 and the support frame 3.

The main technical effect achieved is the creation of a â € œplug and playâ € connection between the connection base 10 and the junction box 11.

In other words, the frame can already be mounted on a building together with the junction box 11, while the photovoltaic glass 2 can already be assembled in the factory with the respective contacts and with the connection base 10, as will be described later.

In this way, on the frame 3 already in place, equipped with a junction box 11, the photovoltaic glass 2 is coupled through the connection base 10 integrated therein.

In order to allow the technical effect described and the plurality of technical effects already described, a suitable method of realization of the photovoltaic system of the invention is provided, which is also part of the present invention.

A frame 3 is provided, preferably comprising an island structure.

From this frame a first through cavity 31 is obtained which will partially house the connection apparatus 1, in particular the junction box 11 of said apparatus.

The through cavity 31 must preferably be shaped like a slot with an internal dimension between 100 and 140mm, preferably 120 mm, with an external dimension between 140 and 180 mm, preferably 160 mm, and with angles made with a radius between 15 ° and 25 °, preferably 20 °.

A plurality of photovoltaic glasses is prepared 2.

The photovoltaic glass 2 is assembled according to a series of successive steps.

With specific reference to Figures 4, 5 and 6, a first glass 2b (or front glass) is provided.

A second cavity 21 with a section substantially coinciding with the section of said first through cavity 31 is obtained from this glass.

A first sheet of PVB (polyvinylbuttyral) or similar material is positioned on said first glass 2b.

On top of this sheet, strings of photovoltaic cells are also arranged according to a predefined design configuration.

In a preferred configuration, 6 lists of 12 cells at most are provided as the connection apparatus 1 is able to host 4 contacts which correspond precisely to the configuration described.

The connection contacts 102 of the strings are then welded onto the structure according to the same predefined design configuration. Preferably, the project configuration is carried out by entering project data through a local or remote interface. In other words, there is a software platform 200 configured to receive requirements generated by a hypothetical customer, validate them in an executive way and generate output data corresponding to one or more of:

â € ¢ bill of materials;

â € ¢ machining cycles with CNC machine language;

â € ¢ system performance;

â € ¢ system production estimate;

â € ¢ hypothetical cost.

Once the first photovoltaic glass layer 2b has been prepared, the connection base 10 is positioned in the second cavity 21 and the connections 102 are inserted in respective terminal blocks 120 (fig.6). This is followed by a test phase of the electrical circuit created.

Once the electrical control operations have been completed, a second sheet of PVB (polyvinylbuttyral) or similar material is placed on the semi-finished product.

The structure of the photovoltaic glass 2 is completed with a second glass 2a (or front glass).

In summary, the preparation of photovoltaic glass 2 includes the steps:

â € ¢ prepare the first glass 2b;

â € ¢ prepare the second glass 2a;

â € ¢ interpose a string of photovoltaic cells between the first glass 2a and the second glass 2b according to a predefined arrangement;

â € ¢ connect the connection base 10 to the photovoltaic glass 2 so that said connection base contacts the string of cells.

In order to allow the connection base 10 to be housed, the total thickness of the glass is preferably at least 12 mm with a rear glass 2b of 8 mm and a front glass 2a with a minimum thickness of 4 mm.

The cavity 21 must be made on the glass 2b preferably in the shape of a slot with an internal dimension between 100 and 140mm, preferably 120 mm, with an external dimension between 140 and 180 mm, preferably 160 mm, and with corners made with a radius between 15 ° and 25 °, preferably 20 °.

The preparation of the photovoltaic glass, as already pointed out, takes place in the factory.

More generally, the photovoltaic glass 2 preparation method does not require that any phase be carried out in the location where the glass will actually be mounted.

On site, ie in correspondence with the building that will house the photovoltaic system, the junction box 11 will be connected to the support frame 3, by inserting it into the first through cavity 31.

The photovoltaic glass 2 (or the plurality of photovoltaic glasses 2) will then be mounted on the support frame 3 on site, so that the connection base 10 and the junction box 11 are removably coupled defining the connection apparatus 1.

According to the invention, the apparatus 1 realizes an electromechanical connection interface between the photovoltaic glass 2 and the support frame 3.

The coupling between glass 2 and frame 3 takes place in such a way that the first through cavity 31 of the frame 3 and the second cavity 21 of the photovoltaic glass 2 are substantially facing each other thus determining a third continuous cavity in which the connection 1.

The connection apparatus 1 will now be described in detail with reference to the attached drawings

The apparatus 1 comprises a connection base (also called â € œcontact bayâ €) which can be connected to the photovoltaic glass and a junction box which can be removed and associated with the connection base and which can be electrically connected to the support frame.

With reference to the figures, figure 3 shows an integrated connection apparatus 1 for a connection between a photovoltaic glass 2 and a respective support frame 3.

With particular reference to the group of figures 1a, 1b and 1c and 3, the apparatus comprises a connection base 10 which can be connected to the photovoltaic glass 2. The connection base 10, according to the invention, comprises a support structure 101 (fig. 1a, 1b).

Preferably, the connection base 10 is laminated directly on the photovoltaic glass and integrates the electrical contacts.

It consists of a support of plastic material, in which electrical contacts are co-molded to which the photovoltaic cells integrated in the glass are connected.

Preferably, the support structure 101 extends mainly along a direction A1-A1 (fig.1a, 1b).

Preferably, this structure has a trapezoid-shaped section, without limiting the use of a convenient structure with a different shape.

Preferably, the support structure 101 is made of plastic material.

The connection base 10, according to the invention, further comprises first electrical contacts 102 projecting from the support structure 101.

Preferably, the first electrical contacts 102 project along transverse directions, in particular perpendicular, to the direction A1-A1.

According to the invention, the first electrical contacts 102 can be associated with the photovoltaic glass 2.

In other words, the first electrical contacts 102 are configured to contact the photovoltaic glass 2 to allow a passage of current.

With particular reference to Figures 2 and 3, the integrated connection apparatus 1 of the invention comprises a junction box 11.

Advantageously, according to the invention, this junction box 11 is removably associated with the connection base 10.

The junction box 11 is electrically connectable to the support frame 3.

In other words, the junction box 11 allows an electrical connection with the support frame 3 of a photovoltaic system.

Preferably, the junction box is made of a plastic polymer.

The junction box (11) extends along a prevalent direction B1-B1 (fig. 2 and 3).

The direction B1-B1 is parallel to the direction A1-A1 of extension of the support structure 101.

Advantageously, according to the invention, the connection base 10 and the junction box 11 determine an electromechanical connection interface between the photovoltaic glass 2 and the support frame 3.

In other words, the connection base 10 and the junction box 11 are physically connected by mechanical and electrical means to allow a connection between the photovoltaic glass 2 and the support frame 3.

With particular reference to Figures 2 and 3, the junction box 11 comprises a box-like body 110.

Preferably, the box-like body 110 comprises two hermetically sealed shells 115, 116.

In particular, the box-like body 110 is made by means of the two shells 115, 116 closed watertight.

According to the invention, the shells 115, 116 enclose spring electric contacts associated with electromechanical insertion means 111.

The junction box 11, in fact, comprises electromechanical insertion means 111 projecting from the box-like body 110.

Preferably, these electromechanical insertion means 111 extend along a transverse direction, in particular orthogonal, to the direction B1-B1 of prevalent extension of the junction box 101. According to the invention, in use, the electric spring contacts associated with the electromechanical means insertion 111 determine a transmission of the electrical energy produced by said photovoltaic glass 2 towards the support structure 3.

Advantageously, according to the invention, the connection base 10 comprises receiving housings 103 formed in the support 101.

Advantageously, according to the invention, the electromechanical insertion means 111 are configured to couple with the receiving housings 103 to provide an electro-mechanical integration interface of the connection apparatus 1.

In other words, the electromechanical insertion means 111, coupled with the receiving housings 103, close the electrical circuit and allow the transmission of the electrical energy produced by the glass to the connection system; this, properly connected, transports the energy to the inverter for transformation at the appropriate levels for use or for feeding into the grid.

In other words, the receiving housings 103 are configured for coupling with the junction box 11, while electromechanical insertion means 111 are configured for coupling with the connection base 10.

Preferably, these electromechanical insertion means 111 are conductive pins.

Preferably, these electromechanical insertion means 111 are configured to associate with the receiving housings 103 with snap coupling.

The shells 115, 116 contain an electronic module provided with bypass diodes, with the functions known in the field of photovoltaic panels.

In particular, the function of the bypass diodes integrated in the junction box is to protect the strings of photovoltaic cells from hot spot phenomena, which can cause overheating and consequent damage to the cells themselves due to partial shading that can obscure part of the facade.

The bypass diodes used include one or more of:

â € ¢ standard diodes;

â € ¢ SMD surface mount diodes;

â € ¢ schottky diodes.

Advantageously, according to the invention, the bypass diodes can comprise cool bypass diodes.

These diodes, unlike the schottky diodes commonly used for this type of applications, offer an advantage in terms of reduced dissipated power, thus increasing the yield of electricity production of photovoltaic glass.

The junction box according to the invention further comprises positioning means 112, 113 projecting from the box-like body 110.

Preferably, these means extend in directions substantially parallel to the projection directions of the electromechanical insertion means 111.

On the other hand, the electrical connection base 10 comprises positioning seats 104, 105 (fig. 1a and 1b) obtained in the support structure 101.

Advantageously, according to the invention, the positioning means 112, 113 and the positioning seats 104, 105 are configured to mutually couple to form the connection apparatus 1 integrated thereby ensuring a mechanical connection between the junction box 11 and the electrical connection base 10.

The junction box 11 also has connectorized cables 117 which extend out from the box-like body 110 along the direction B1-B1 and which can be connected to the support frame 3.

The junction box 11 also comprises hermetic cable glands 118 configured to house the connectorized cables 117.

According to the invention, at least one of the hermetic cable glands 118 comprises an osmotic valve configured to allow air to enter / exit the junction box 11 by balancing the pressure differences between the internal volume and the external environment.

This choice allows to obtain the watertightness of the junction box and guarantees a balancing of the pressure with the external environment thus avoiding the deformation of the junction box, in case of increase of the internal pressure due to the temperature increase due to the power dissipated by the diodes when they are in action to protect the cell strings from the shading of the facade.

This choice also makes it possible to prevent any breakage of the shell due to internal overpressure.

In summary, the invention facilitates the assembly of photovoltaic glass to the respective metal frames.

This allows an optimization of costs and a drastic reduction in breakdowns, as well as the elimination of problems due to incorrect assembly or damage to the glass due to electrical connections not performed in a workmanlike manner.

Further, the invention makes it possible to make the electrical connection invisible, which remains hidden partly in the metal upright of the frame and partly in the photovoltaic glass, thereby guaranteeing ample margins of creativity to the architects and designers of the photovoltaic facades, who draw from it therefore technical and aesthetic advantages, as well as functional ones.

The invention also guarantees that the construction of the photovoltaic modules can be carried out in the factory, so that the islands of modules made can be connected on site to the modules already installed on the facade, simply by connecting the connectors already prepared in the metal frame. , with enormous advantages in terms of reduction of installation times and consequent reduction of costs.

Advantageously, according to the invention, the photovoltaic system described also comprises a control unit 50 (fig. 5), in data connection with the connection apparatus 1, and configured to manage, monitor and process data from from the connection device 1.

According to the invention, the control unit 50 comprises a memory module 51 configured for a collection of monitoring data of the integrated photovoltaic system.

According to the invention, the control unit 50 further comprises an operating module 52 configured to monitor and manage the integrated photovoltaic system.

Management / configuration can take place locally or remotely.

Advantageously, according to the invention, the design configuration described in the method is carried out by entering design data by means of a local or remote interface.

In other words, the system of the invention comprises a software platform 200 configured to receive input requirements generated by a hypothetical customer and validate them in an executive way.

The software platform 200 is also configured to generate output data corresponding to one or more of:

â € ¢ bill of materials;

â € ¢ machining cycles with CNC machine language;

â € ¢ system performance;

â € ¢ system production estimate;

â € ¢ hypothetical cost.

In general, it should be noted that in the present context and in the subsequent claims, the control unit 50 is presented as subdivided into distinct functional modules (memory modules or operating modules) for the sole purpose of describing its functionality in a clear and complete manner.

This control unit 50 can be constituted by a single electronic device, suitably programmed to perform the described functions, and the different modules can correspond to hardware entities and / or software routines forming part of the programmed device.

Alternatively or in addition, these functions can be performed by a plurality of electronic devices on which the aforementioned functional modules can be distributed.

The control unit 50 can also use one or more processors to execute the instructions contained in the memory modules.

The aforementioned functional modules can also be distributed on different computers locally or remotely based on the architecture of the network in which they reside.

Claims (10)

CLAIMS 1. Integrated photovoltaic system comprising: â € ¢ a modular support frame (3) comprising at least a first through cavity (31) formed in a substantially peripheral position of said frame; â € ¢ a plurality of photovoltaic glasses (2) mounted on said modular support frame (3) in which at least one of said photovoltaic glasses (2) comprises a second substantially perimeter cavity (21); â € ¢ a connection apparatus (1), for a connection between said plurality of photovoltaic glasses (2) and said support frame (3), at least partially housed in said first substantially perimeter through cavity (31), in which said apparatus (1) comprises: o a connection base (10) adapted to be connected to said photovoltaic glass (2); or a junction box (11) removably associated with said connection base (10) and able to be electrically connected to said support frame (3), wherein said connection base (10) and said junction box (11) determine an electromechanical connection interface between said photovoltaic glass (2) and said support frame (3). 2. Integrated photovoltaic system according to claim 1 wherein said connection base (10) comprises: â € ¢ a support structure (101); â € ¢ first electrical contacts (102) projecting from said support structure (101) along directions transverse to the prevalent direction (A1-A1) of extension of said support (101), said first electrical contacts (102) being able to be associated to said photovoltaic glass (2); â € ¢ receiving housings (103) formed in said support (101) and configured for coupling with said junction box (11). and said junction box (11) comprises: â € ¢ a box-like body (110); â € ¢ electromechanical insertion means (111) projecting from said box-like body (110) along a direction orthogonal to a prevalent direction (B1-B1) of extension of said junction box (101) and configured to couple with said receiving housings (103) to provide an electro-mechanical interface for integrating said electrical connection apparatus (1); â € ¢ connectorized cables (117) extending out from said box-like body (110) along said direction (B1-B1) and adapted to be connected to said support frame (3). 3. Integrated photovoltaic system according to claim 2 wherein said junction box (11) comprises positioning means (112, 113) projecting from said box-like body (110) in directions substantially parallel to the overhang directions of said electromechanical insertion means ( 111), and said an electrical connection base (10) comprises in said support structure (101) positioning seats (104, 105), wherein said positioning means (112, 113) and said positioning seats (104, 105) are configured to mutually couple to make said connection apparatus (1) integrated thereby ensuring a mechanical connection between said junction box (11) and said electrical connection base (10). Integrated photovoltaic system according to any one of claims 2 or 3, wherein the box-like body (110) comprises two hermetically sealed shells (115, 116) which contain an electronic module provided with bypass diodes. Integrated photovoltaic system according to any one of claims 2 to 4 wherein said junction box (11) comprises hermetic cable glands (118) configured to house said connectorized cables (117). 6. Integrated photovoltaic system according to claim 5 wherein at least one of said hermetic cable glands (118) comprises an osmotic valve configured to allow air to enter / exit said junction box (11) by balancing the pressure differences between internal volume and external environment. 7. Integrated photovoltaic system according to any one of the preceding claims, further comprising a control unit (50), in data connection with said connection apparatus (1), and configured to manage, monitor and process data from said control apparatus connection (1). Integrated photovoltaic system according to claim 7 wherein said control unit (50) comprises a memory module (51) configured for a collection of monitoring data of said integrated photovoltaic system. Integrated photovoltaic system according to claim 7 or 8 wherein said control unit (50) comprises an operating module (52) configured to monitor and manage said integrated photovoltaic system. 10. Method of realization of an integrated photovoltaic system comprising the phases of: â € ¢ prepare a modular support frame (3) comprising an island structure; â € ¢ making at least a first through cavity (31) in said support frame (3); â € ¢ electrically connect a junction box (11) to said support frame (3). â € ¢ prepare a plurality of photovoltaic glasses (2); â € ¢ obtaining a second cavity (21) in at least one glass of said plurality of said photovoltaic glasses (2); â € ¢ connecting a connection base 10 to said photovoltaic glass 2 so that said connection base is housed in said second cavity (21); â € ¢ mount said plurality of photovoltaic glasses (2) on said support frame (3) so that said connection base (10) and said junction box (11) are removably coupled defining a connection apparatus (1) which realizes an electromechanical connection interface between said photovoltaic glass (2) and said support frame (3).