Description:FIELD OF INVENTION
[001] The field of invention generally relates to solar energy technologies. More specifically, it relates to a flexible solar module and method thereof.

BACKGROUND
[002] The solar energy industry has experienced substantial growth over the past few decades, driven by the demand for renewable and sustainable energy sources. Solar technology is increasingly applied in residential, commercial, and industrial sectors, providing an effective means of generating clean energy. Innovations in solar modules, materials, and installation techniques have made it possible to integrate solar energy systems into a wide variety of surfaces and structures, broadening their practical applications and making solar energy more accessible.
[003] Currently, existing systems do not succeed in providing a solar module that is both lightweight and flexible, while also being easy to install on diverse building surfaces. Traditional solar modules are typically mounted using rigid frames and mounting structures that add significant weight and complexity. These conventional modules often require specialized labor and equipment for installation, limiting their adaptability, especially on surfaces that cannot support heavy loads or require a more integrated appearance. Furthermore, the glass and metal materials used in standard solar modules contribute to their overall weight, making them difficult to transport, install, and maintain.
[004] Other existing systems have tried to address this problem. However, their scope was limited to reducing the weight of the solar panels without significantly enhancing installation ease or flexibility. For instance, some designs replaced glass with lightweight polymers, but they still relied on traditional mounting frames and brackets. These systems do not adequately support a direct adhesive mounting approach, which could enable for a seamless integration of solar modules on a variety of surfaces without the need for additional support structures. Moreover, such attempts often sacrifice durability or efficiency, leading to systems that are either fragile or less effective in energy generation.
[005] Thus, in light of the above discussion, it is implied that there is need for a flexible solar module and method thereof, which is reliable and does not suffer from the problems discussed above.
 
OBJECT OF INVENTION
[006] The principal object of this invention is to provide a flexible solar module and method thereof.
[007] Another object of the invention is to design a solar module that significantly reduces weight compared to conventional modules, enabling easier transportation, handling, and installation, particularly on surfaces with limited structural support.
[008] Another object of the invention is to facilitate direct attachment of the solar module to building surfaces using an adhesive layer, eliminating need for traditional mounting structures and frames, and thereby reducing installation complexity and cost.
[009] Another object of the invention is to incorporate encapsulation layers that secure and protect at least one solar cell, ensuring the flexible solar module withstands environmental factors such as UV exposure, moisture, and temperature variations while maintaining long-term durability.
[0010] Another object of the invention is to use advanced cell connection methods, such as the Super Multi Bus Bar (SMBB) technology and a series-then-parallel configuration, to optimize current flow, reduce resistance losses, and maximize energy output.
[0011] Another object of the invention is to develop a flexible solar module that can be applied on various surfaces, comprising non-traditional or uneven surfaces.
[0012] Another object of the invention is to utilize composite and polymer materials that reduce overall material costs, enabling a more affordable production process, and to streamline installation by enabling direct adhesive mounting, thereby reducing labor costs.
[0013] Another object of the invention is to create a low-profile solar module that can seamlessly integrate with building aesthetics, especially on walls and roofs, without bulky frames or mounting structures.
[0014] Another object of the invention is to use materials that not only reduce weight but also have a lower environmental footprint, aiming for a sustainable, eco-friendly design that aligns with the renewable energy industry’s sustainability goals.

BRIEF DESCRIPTION OF FIGURES
[0015] This invention is illustrated in the accompanying drawings, throughout which, like reference letters indicate corresponding parts in the various figures.
[0016] The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0017] Figure 1 depicts/illustrates an exploded view of a flexible solar module, in accordance with an embodiment;
[0018] Figure 2 depicts/illustrates a front view of a flexible solar module, in accordance with an embodiment;
[0019] Figure 3 illustrates a method for manufacturing a flexible solar module, in accordance with an embodiment.

STATEMENT OF INVENTION
[0020] The present invention discloses a flexible solar module provides an efficient, lightweight, and adaptable solution for solar energy capture, suitable for a variety of installation environments. The invention comprises a composite substrate layer that offers structural support and flexibility, enabling the module to conform to diverse surfaces. Over the composite substrate layer, an encapsulation layer is disposed to secure and protect at least one solar cell, which is arranged in a half-cell configuration to enhance durability and optimize electrical efficiency. A transparent top sheet is positioned above the solar cell to facilitate sunlight penetration while shielding the internal components from environmental factors such as UV radiation, moisture, and temperature variations.
[0021] Additionally, the invention comprises an adhesive layer positioned under the composite substrate layer, enabling direct mounting onto surfaces without the need for traditional frames or mounting structures. This design simplifies installation, reduces associated costs, and broadens application potential. The solar cells are connected using Super Multi Bus Bar (SMBB) technology, improving current flow, minimizing resistive losses, and thereby maximizing energy output. A white back sheet is positioned under the busbar, configured to increase reflectivity and enhance energy absorption efficiency.
[0022] The invention’s flexible design and installation method make it applicable to a wide range of uses, comprising building-integrated photovoltaics, vehicle-integrated photovoltaics, portable solar solutions, and off-grid installations. By addressing the limitations of conventional rigid modules, the present invention offers a reliable, cost-effective, and aesthetically integrated solution for expanding solar energy deployment across various environments.
 
DETAILED DESCRIPTION
[0023] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and/or detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0024] The present invention discloses a flexible, lightweight solar module which enables direct adhesive mounting, and is designed to simplify installation and expand solar energy applications. The invention comprises a composite substrate layer for flexibility, a half-cell solar configuration connected using Super Multi Bus Bar (SMBB) technology for enhanced efficiency, and protective encapsulation and top layers to shield against environmental factors. An adhesive layer enables the module to be directly mounted on various surfaces, comprising curved and irregular structures, without the need for traditional mounting frames. This design reduces installation costs and broadens potential applications, making it ideal for building-integrated photovoltaics, vehicle surfaces, portable solar solutions, and other non-traditional installations.
[0025] Figure 1 depicts/illustrates a flexible solar module 100 comprising a composite substrate layer 102, at least one encapsulation layer 104, a white back sheet 106, a busbar 108, at least one solar cell 110 in a half-cell configuration, and a transparent top sheet 112.
[0026] In an embodiment, the composite substrate layer 102 forms the foundational layer of the module and is configured to provide structural support while maintaining flexibility. Composite substrate layer 102 comprises at least one of: polymer, metal, or sandwiched composite, among others, to reduce the overall weight of the module by up to 50% compared to conventional modules with glass substrates. Advantageously, the composite substrate layer 102 enables the module to conform to various surfaces, making it suitable for diverse applications, such as building facades, vehicle surfaces, or curved installations. The lightweight and flexible nature of composite substrate layer 102 also facilitates easier handling, transport, and installation.
[0027] In an embodiment, the at least one encapsulation layer 104 is disposed above the composite substrate layer 102 and is configured to secure and protect the components positioned above, particularly the solar cell 110 and busbar 108. The at least one encapsulation layer 104 comprises ethylene-vinyl acetate (EVA) or similar polymer materials that provide environmental protection and thermal stability.
[0028] Advantageously, the encapsulation layer 104 shields internal components from moisture, dust, and physical impacts, thereby extending the operational life of the module. This protective layer enhances the module’s durability and makes it suitable for outdoor installations, ensuring long-term reliability in various environmental conditions.
[0029] The white back sheet 106 is positioned under the busbar 108, which serves to enhance the energy absorption efficiency of the module by reflecting unused sunlight back towards the solar cell 110. The white back sheet 106 is configured from durable, reflective materials that maintain high reflectivity under various environmental conditions. Advantageously, the white back sheet 106 increases energy capture efficiency, particularly in low-light scenarios, maximizing the module's output and improving performance in suboptimal lighting conditions.
[0030]
[0031] In an embodiment, the busbar 108 is disposed above the white back sheet 106 and is configured to connect the solar cell 110. The busbar 108 utilizes Super Multi Bus Bar (SMBB) technology, which provides multiple contact points across the solar cell 110, reducing resistive losses and optimizing current flow. Advantageously, the SMBB technology in busbar 108 enhances the electrical efficiency of the module by minimizing power loss and distributing electrical loads more evenly, which helps prevent localized overheating and prolongs the operational lifespan of solar cell 110. This feature makes busbar 108 particularly suitable for high-efficiency solar applications.
[0032] In an embodiment, the busbar 108 comprises a white back sheet 106 positioned under the busbar 108 and size of the white black sheet 106 configured to match the area of the busbar 108 to increase reflectivity and improve energy absorption.
[0033] In an embodiment, the solar cell 110 is disposed above the busbar 108 and positioned in a half-cell configuration, which divides each solar cell into two halves to reduce thermal stress and improve efficiency. The half-cell configuration enables solar cell 110 to generate electrical energy more effectively by minimizing power losses and lowering operational temperatures. Advantageously, the solar cell 110 in a half-cell configuration provides both enhanced energy output and improved durability, making the module reliable in a variety of environmental conditions.
[0034] Above the solar cell 110 is the at least one encapsulation layer 104 again, which provides additional environmental protection, mirroring the function of the lower encapsulation layer. The at least one encapsulation layer 104 comprises materials such as EVA or other protective polymers that shield the solar cell 110 and busbar 108 from physical impacts, UV radiation, and environmental exposure. Advantageously, by sandwiching the solar cell 110 and busbar 108 between encapsulation layers 104, the module achieves comprehensive protection, ensuring that internal components remain secure and functional even in harsh environmental conditions.
[0035] In an embodiment, the transparent top sheet 112 is the outermost layer of the module, positioned above the upper encapsulation layer. Transparent top sheet 112 comprises high-transparency materials, such as specialized polymers, that enable sunlight to penetrate the module while protecting the internal components from environmental factors such as UV radiation, moisture, and physical wear. Transparent top sheet 112 may further comprise an anti-reflective coating to enhance light transmission, maximizing the efficiency of solar cell 110. Advantageously, the transparent top sheet 112 enables maximum sunlight exposure while safeguarding the module’s longevity and performance in outdoor environments.
[0036] an adhesive layer disposed under the composite substrate layer 102, configured to directly mount the flexible solar module 100 to a building surface without additional mounting structures. The adhesive layer comprises a high-bond adhesive suitable for attaching the flexible solar module 100 to a surface, with or without additional fasteners.
[0037] Advantageously, the flexible solar module 100 achieves high performance and adaptability, making it suitable for a variety of applications where conventional rigid solar modules are impractical. The design enables the flexible solar module 100 to be mounted on various surfaces, such as building exteriors, vehicles, and portable installations, expanding the range of potential applications and facilitating the deployment of solar energy across diverse environments.
[0038] Weight of the flexible solar module is approximately 13 to 15 kilograms, significantly reducing the weight compared to conventional solar panels that weigh approximately 29 kilograms, thereby enabling easier transportation, handling, and installation, particularly on surfaces with limited structural support.
[0039] Figure 2 depicts/illustrates a cross-sectional, layered view of the flexible solar module 100, showing the arrangement of each component from the base to the top.
[0040] In an embodiment, the encapsulation layer 104 comprises a first encapsulation layer 104a disposed above the composite substrate layer 102 and configured to secure and protect the solar cell 110; a second encapsulation layer 104b disposed above the solar cell 110, configured to shield the solar cell 110 from environmental factors; and a third encapsulation layer 104c disposed between the white back sheet 106 and the solar cell 110, configured to provide additional structural stability and environmental protection to the solar cell 110.
[0041] Figure 3 illustrates a method 300 for manufacturing a flexible solar module. The method begins with providing a composite substrate layer configured to provide structural support and flexibility, as depicted at step 302. Subsequently, the method 300 discloses disposing at least one encapsulation layer over the composite substrate layer, configured to secure and protect at least one solar cell, as depicted at step 304. Thereafter, the method 300 discloses placing the at least one solar cell in a half-cell configuration over the encapsulation layer, wherein the at least one solar cell is configured to generate electrical energy from sunlight, as depicted at step 306. Thereafter, the method 300 discloses positioning a transparent top sheet above the at least one solar cell, configured to enable sunlight penetration while protecting the at least one solar cell, as depicted at step 308. Thereafter, the method 300 discloses applying an adhesive layer under the composite substrate layer 102, configured to directly mount the flexible solar module to a surface without additional mounting structures, as depicted at step 310.
[0042] The advantages of the current invention include:
[0043] Lightweight Design: The invention achieves significant weight reduction—up to 50% compared to traditional solar modules with glass encapsulation—making it easier to handle, transport, and install on various surfaces, comprising walls and roofs with limited load-bearing capacity.
[0044] Enhanced Flexibility: The use of a composite substrate layer and advanced encapsulation materials enables the module to conform to non-flat or curved surfaces, making it suitable for applications in building-integrated photovoltaics (BIPV) and other structures that require adaptable form factors.
[0045] Simplified Installation with Direct Adhesive Mounting: The adhesive layer enables the module to be directly mounted on building surfaces without additional mounting structures, reducing installation time and costs. This adhesive approach also enables for seamless aesthetic integration, particularly on modern architectural surfaces.
[0046] Improved Electrical Efficiency: The half-cell configuration combined with Super Multi Bus Bar (SMBB) technology optimizes current flow and reduces resistive losses, resulting in improved energy generation efficiency compared to conventional modules. This design also minimizes thermal stress, enhancing the durability and performance of the solar cells.
[0047] Durability and Environmental Protection: The encapsulation layers provide robust protection against environmental factors, such as UV radiation, moisture, dust, and physical impacts, ensuring long-term stability and performance of the solar module in diverse weather conditions.
[0048] Increased Energy Absorption: The white back sheet reflects unused sunlight back towards the solar cells, increasing the overall energy absorption and efficiency, particularly in low-light conditions. This reflective feature makes the module more effective even in shaded or less optimal lighting environments.
[0049] Cost-Effectiveness: By eliminating the need for traditional glass and mounting structures, the invention reduces both material and installation costs. The composite and polymer-based materials are also less expensive and easier to source than traditional solar glass, making module more affordable.
[0050] Aesthetic Integration: The low-profile design without bulky frames or rails enables for better visual integration with building exteriors, supporting the aesthetics of modern architecture. This advantage is especially valuable for residential and commercial applications where appearance is an important factor.
[0051] Versatile Application Range: The flexible and lightweight nature of the invention enables it to be used on a wide range of surfaces, comprising roofs, walls, facades, and even unconventional or non-structural surfaces, broadening the potential for solar energy deployment.
[0052] Reduced Environmental Impact: By using lighter materials and reducing the amount of glass and metal required, the invention lowers the overall environmental footprint. The flexibility and durability also contribute to longer module life, reducing the frequency of replacements and waste over time.
[0053] Enhanced Safety in Installation and Maintenance: The lightweight, adhesive-mounted design reduces the risks associated with heavy mounting systems and complex installations, leading to safer installation processes. Maintenance is also simplified, as the module can be more easily handled without heavy framing.
[0054] Increased Adaptability to Future Innovations: The modular design and material choices make it possible to integrate additional advancements, such as improved photovoltaic materials or advanced adhesives, enhancing the flexible solar module adaptability to future technological developments.
[0055] Applications of the current invention include:
[0056] Building-Integrated Photovoltaics (BIPV): The flexible solar module is ideal for integration into building facades, walls, and roofs, where its lightweight and adaptable design enables seamless aesthetic integration without the need for bulky mounting structures. BIPV installations can significantly reduce a building's energy consumption by harnessing solar power directly on the building envelope.
[0057] Rooftop Solar Systems: The invention can be used on residential, commercial, and industrial rooftops, comprising those with limited load-bearing capacity. Its lightweight construction reduces stress on the roof structure, and the adhesive mounting simplifies installation, making it an efficient option for new constructions and retrofits.
[0058] Curved and Irregular Surfaces: The flexible nature of the module enables it to be installed on curved, angled, or irregular surfaces that are unsuitable for conventional rigid solar panels. This application is beneficial for structures with architectural features like domes, arches, or slanted walls.
[0059] Off-Grid and Remote Installations: Due to its lightweight and easily transportable design, the invention is suitable for off-grid solar installations in remote or rural areas where traditional modules and mounting systems are challenging to transport and install. These modules can provide reliable power for rural homes, schools, medical centers, and emergency shelters.
[0060] Portable Solar Power Solutions: The invention can be used in portable solar power systems, such as foldable solar panels, rollable solar chargers, and lightweight solar mats. These solutions are beneficial for outdoor activities, camping, disaster relief operations, and military field deployments, providing a convenient and compact source of renewable energy.
[0061] Agricultural Applications (Agri-Photovoltaics): The flexible solar module can be used in agricultural environments, such as greenhouse rooftops or over crop fields, where its lightweight design minimizes shading and impact on plant growth. Agri-PV systems enable dual land use for both agriculture and energy production, increasing the efficiency of land resources.
[0062] Vehicle-Integrated Photovoltaics (VIPV): The module is suitable for integration into vehicle surfaces, such as the roofs and hoods of electric vehicles, buses, trucks, boats, and RVs, providing supplementary power to the vehicle's battery. The flexible, lightweight module minimizes the impact on vehicle aerodynamics and weight while enabling renewable energy capture on the go.
[0063] Temporary and Mobile Installations: The adhesive-mounted flexible solar module is ideal for temporary installations on mobile units, such as shipping containers, pop-up structures, tents, and exhibition booths. This feature is useful for events, trade shows, and emergency setups where quick, tool-free installation is required.
[0064] Urban Infrastructure and Public Spaces: The invention can be applied to urban infrastructure, such as bus stops, street lighting, park benches, and other public amenities, where it can provide off-grid power for lighting, Wi-Fi, and device charging stations. The direct adhesive mounting simplifies integration into urban structures, supporting the development of smart cities.
[0065] Solar-Powered Shelters and Canopies: The module can be used to create solar-powered shelters, carports, canopies, and pergolas, which provide shade and simultaneously generate clean energy. This application is beneficial for parking lots, parks, residential yards, and commercial outdoor spaces, where it can offset grid electricity use.
[0066] Temporary Power Supply for Construction Sites: The invention can provide a convenient power source for construction sites, particularly in remote locations where traditional grid power is unavailable. The ease of installation and transport makes it suitable for powering small equipment, lighting, and temporary offices on-site.
[0067] Floating Solar Systems: The lightweight and flexible design of the module makes it suitable for floating solar installations on bodies of water, such as reservoirs, lakes, and ponds. Floating solar systems maximize land usage and reduce water evaporation, making them ideal for water-scarce regions.
[0068] Smart Home and IoT Device Integration: The flexible solar module can be adapted for smaller, low-power IoT applications, such as powering sensors, cameras, and smart home devices. The adhesive mounting enables for easy attachment to various surfaces, enabling decentralized solar power generation for connected devices.
[0069] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the embodiments as described here.
, Claims:We claim:
1. A flexible solar module (100), comprising:
a composite substrate layer (102) configured to provide structural support and flexibility;
at least one encapsulation layer (104) configured to secure and protect at least one solar cell (110);
the at least one solar cell (110) disposed above the least one encapsulation layer (104) in a half-cell configuration;
a transparent top sheet (112) disposed above the at least one solar cell (110), configured to enable sunlight penetration while protecting the at least one solar cell (110); and
an adhesive layer disposed under the composite substrate layer (102), configured to directly mount the flexible solar module to a surface.

2. The flexible solar module (100) as claimed in claim 1, wherein the composite substrate layer (102) comprises a composite material comprising at least one of metal, polymer, sandwiched composite, or clear transparent material.

3. The flexible solar module (100) as claimed in claim 1, wherein the at least one encapsulation layer (104) comprises:
a first encapsulation layer (104a) disposed above the composite substrate layer (102) and configured to secure and protect the at least one solar cell (110);
a second encapsulation layer (104b) disposed above the solar cell (110), configured to shield the solar cell (110) from environmental factors; and
a third encapsulation layer (104c) disposed between the white back sheet (106) and the solar cell (110), configured to provide additional structural stability and environmental protection to the solar cell (110).

4. The flexible solar module (100) as claimed in claim 1, wherein the encapsulation layer (104) comprises at least one of a ethylene-vinyl acetate (EVA).

5. The flexible solar module (100) as claimed in claim 1, wherein the adhesive layer comprises a high-bond adhesive suitable for attaching the flexible solar module to a surface, with or without additional fasteners.

6. The flexible solar module (100) as claimed in claim 1, wherein the at least one solar cell (110) is connected in a series-then-parallel configuration to optimize current flow and reduce electrical losses.

7. The flexible solar module (100) as claimed in claim 1, comprising a busbar (108) disposed under the at least one solar cell (110), configured to connect the at least one solar cell (110), utilizing Super Multi Bus Bar (SMBB) technology to optimize current flow and reduce resistive losses.

8. The flexible solar module (100) as claimed in claim 7, wherein the busbar (108) comprises a white back sheet (106) positioned under the busbar (108), and wherein size of the white black sheet (106) is configured to match an area of the busbar (108) to increase reflectivity and improve energy absorption.

9. The flexible solar module (100) as claimed in claim 1, wherein weight of the flexible solar module is approximately 13 to 15 kilograms.

10. A method for manufacturing a flexible solar module, comprising:
providing a composite substrate layer (102) to provide structural support and flexibility;
disposing at least one encapsulation layer (104) above the composite substrate layer (102), to secure and protect at least one solar cell;
placing the at least one solar cell (110) in a half-cell configuration over the encapsulation layer (104);
positioning a transparent top sheet (112) above the at least one solar cell (110), to enable sunlight penetration while protecting the at least one solar cell (110); and
applying an adhesive layer under the composite substrate layer (102), to directly mount the flexible solar module to a surface without additional mounting structures.

11. The method as claimed in claim 9, comprising forming the composite substrate layer (102) from a composite material comprising at least one of metal, polymer, sandwiched composite, or clear transparent material.

12. The method as claimed in claim 9, comprising disposing the at least one encapsulation layer (104) comprises:
disposing a first encapsulation layer (104a) above the composite substrate layer (102), configured to secure and protect the at least one solar cell (110);
disposing a second encapsulation layer (104b) above the solar cell (110) to shield the solar cell (110) from environmental factors; and
disposing a third encapsulation layer (104c) between a white back sheet (106) and the solar cell (110), configured to provide additional structural stability and environmental protection to the solar cell (110).

13. The method as claimed in claim 9, comprising connecting the at least one solar cell (110) in a series-then-parallel configuration to optimize current flow and reduce electrical losses.

14. The method as claimed in claim 9, comprising disposing a busbar (108) under the at least one solar cell (110) to connect the at least one solar cell (110), and wherein the busbar (108) utilizes a Super Multi Bus Bar (SMBB) to optimize current flow and reduce resistive losses.

15. The method as claimed in claim 13, comprising positioning a white back sheet (106) under the busbar (108) and wherein size of the white black sheet (106) is configured to match an area of the busbar (108) to increase reflectivity and improve energy absorption.

Date: 25th November, 2024

Signature:
Name of signatory: Nishant Kewalramani
(Patent Agent) IN/PA number: 1420