STILORMADE modules use specific metallization patterns to improve generated current collection while improving general aesthetic aspect. Three computer programs were developed by TU Wien (AT) in order to optimize the design of the metallization pattern, generate cell layout and improve their interconnection in PV modules (Fig. 3). More than 1,000 variations in design (number of collecting fingers, finger width) were tested and lead to a theoretical increase of absolute cell efficiency of 0.5%, hence values above 18% on multi-crystalline silicone with standard Al-BSF structures. Manufacturing processes including specific metallization process and pad to pad interconnection step of i-Cell modules were improved and optimized on more than 10,000 cells.
A technology production line for PV module was implemented in S’Tile’s premises (FR). It was successfully tested by manufacturing modules with wide variability of technical requirements as requested by potential partners approached during a market potential and business opportunities study (Figure 4). This range of modules covers applications such as charging stations, solar Street lights, solar roof tiles, weather station. The specific pad to pad cell interconnection process allows the string of cells to adapt to curved shapes to some extent. S’Tile developed a particular laminating process to manufacture modules with different shapes that could give birth to new market opportunities (Fig. 5 and 6).
STILORMADE innovation was successfully tested through load resistance (snow, wind, hails), long term performance and ageing (thermal cycling, UV resistance etc.). Market readiness was finally demonstrated thanks to successful testing to all relevant standards of PV industry (IEC 612215 and 61730-1,2).
Stakeholder engagement and market reviews performed for customized (non-standard) modules have shown an important business opportunity for STILORMADE modules in Building Integration PhotoVoltaics (BIPV) and urban furniture such as Solar Street Lights (SSL). These two applications were addressed to validate performance and benefits of the product.
For BIPV: i) A solar shading system for building facades was developed and implemented in a building in Barcelona with a total power of 8.6 kWp (Fig. 7 and 8). ii) Solar roofing system was designed and was used to cover the roof of city center market of Montpellier in France: “Les Halles de Laissac” for a total power of 69 kWp (Figure 9 and 10).
For SSL: Two models were designed demonstrating unique features and visual appeal provided by the STILORMADE modules (Fig. 11 and 12). These SSL can work independently of electrical grid thanks to smart battery management systems. 26 units were implemented in Spain, Israel and Austria.
Implemented system are under active monitoring and were already validated in terms of attractiveness, energy performance and contribution to global PV energy acceptation.
Dissemination of the project results and outcome was performed to showcase market replication activities and STILORMADE possibilities. Channels such as fairs, conferences, publications, face to face meetings gave rise to an important database of prospects and potential early adopters. As a result, first agreements of a total of 338 k€ were already concluded for fall systems dedicated to solar roofing and solar street lights.
