The Race to Make Solar Energy Smarter
In the world of renewable energy, thin film solar panels are making waves. This is why.
These thin-film solar panels are made by stacking very thin layers of photovoltaic material on top of a base, which can be metal, plastic, or even glass. This is different from the heavy, bulky crystalline silicon panels. What happened? Solar panels that are light, bendable, and sometimes even transparent. That makes it easy to add them to modern buildings. In cities, where rooftops, walls, and design limits need solutions that not only work but also look good, their versatility with solar technology really shines.
Overview of Thin-Film Solar Panels
Modern buildings can really benefit from thin film solar panels. Because they are so light, these film solar panels don't need a lot of extra support to stay on rooftops. They can also bend, so they can go around curved walls or windows. This is great for architects who want to be creative with solar panel design.
They also don't have as much trouble in tough situations. Not much light? Is it hot outside? These solar panels keep going when regular panels start to slow down. Researchers at MIT even made ultrathin solar cells that are 100 times lighter than regular panels and can stick to almost any surface.
Why Structural Engineering Is Important for Thin-Film Panels
Most of the time, thin-film modules are made as one piece, which makes it much easier to put them together. But putting up thin film solar panels still needs careful structural engineering.
Engineers need to check the panels' load-bearing capacity, wind resistance, and thermal expansion to make sure they are properly and securely attached to the building. It's also important to think about how to mount it, whether it will work with the materials you already have, and how well these modules will hold up over time in harsh conditions.
Structural engineers also need to work closely with architects and energy experts to make sure that thin film solar systems work as well as possible and last as long as possible while keeping the building safe and sound.
Types and Composition of Film Solar Cells
People usually group thin film solar panels by the type of photovoltaic semiconductor material they use. The three most common types are:
Amorphous Silicon (A-Si) is a type of silicon that is not crystalline. It is put down in thin layers, which makes it very light and flexible. It's often used for building-integrated photovoltaics (BIPV), where the shape and look of the solar panels are very important.
Cadmium Telluride (CdTe): These solar panels are known for being very efficient and cheap to make. What's the catch? It's still hard to scale them up, and there are environmental concerns because tellurium is rare and cadmium is toxic.
Copper Indium Gallium Selenide (CIGS): These thin-film solar cells are a good balance between solid efficiency and flexibility. They are great for portable applications or curved surfaces because you can mount these film panels on bendable materials.
Advantages of Thin Film Solar Panels
We've already talked about the benefits, but let's go over the main points again in a clear and simple way:
Lightweight: Thin film panels don't add much weight, so even older roofs can support these solar panels without needing extra support. No heavy lifting or too many supports.
Flexibility: Amorphous silicon and CIGS panels can bend. Bend in real life. That means these film solar panels can handle walls that are curved, windows that are angled, and designs that are out of the ordinary.
Looks that fit in: These solar panels don't scream "solar," so they fit in well. They come in colors, even semi-transparent ones, so they blend in with walls, glass, and any other surface you put them on.
Heat-friendly: When the temperature goes up, most solar panels lose their edge. What is a thin film? They keep going. That lower temperature coefficient keeps these cells stable in the heat.
Lower cost: Less hassle, less energy, and less material mean lower costs for solar technology. They are less expensive to make and easier to put up, with little extra work and cost.
Limitations of Film Solar Panels
Thin film solar panels have a lot of great features, but they also have some problems:
Lower Efficiency: They just don't get as much solar energy from the sun. Silicon can make 15–20% efficiency, but thin film only makes 11–12% efficiency. You need to put down more panels, more space, and more of everything else to keep up.
Shorter Lifespan and Less Durable: They're not built like tanks. Nature wears these solar panels down faster when it's hot, cold, or stormy. Over time, they get weaker, work less well, and can't last as long as silicon panels.
Need more space: You need to cover more ground to get the same output because these film panels produce less per panel. That makes them hard to use on small rooftops or in places where space is tight.
Installation-Related Structural Considerations for Thin Film Solar
When putting up thin-film solar panels, we need to think about the structure. Let's look at what we need to think about for solar panel installation.
How to Figure Out Roof Load Capabilities:
Thin film solar panels are much lighter than regular ones, averaging about 3.5 kg/m² (CIGS). That means a dead load of only 0.35 kN on a roof that is 100 m². Even though that's a small load, it still needs to be compared to the roof's structural strength, especially in older buildings.
Wind Load Factors:
Wind can put a lot of pressure on the sides of solar panels and even lift them straight up, especially if they are tilted or raised. That's why engineers need to pay close attention to things like:
The height of the building and the type of exposure, such as urban vs. open space.
Type of mounting system: Mechanically connected systems hold these film solar panels better when the wind blows. They are locked into the structure itself, not just sitting there with weight holding them down like setups with ballast.
Design rules: Use ASCE 7-10 or ASCE 7-16 to figure out how much wind will hit the building.
Things to think about for snow load:
In places with cold weather, snow can build up unevenly and put more stress on the solar panels. To fight that, think about things like:
Panel tilt: Steeper slopes make it easier for snow to fall naturally off solar cells.
Drift zones: Snow never spreads out evenly. The wind moves it around and stacks it in odd places. Edges and parapets are places where heavy drifts that weigh a lot more than you think tend to stick.
Following ASCE 7 and any local changes is important when figuring out how much snow will fall.
Ways to Attach: Comparing Mechanical Fastenings to Adhesive Applications:
For conventional solar panels to work, they need mechanical structures that can hold their weight, keep them up, and attach them to roofs or other base structures. You can also install thin film panels like that, but if you don't do the installation right, they could leak or rust.
Because thin film panels are so light, they can also be put up with structural adhesive. Structural adhesives keep roofs from getting too heavy and don't need much work to put in for installation. Adhesives can be a good way to hold solar panels in place without ruining the look of a roof, but they need to be strong. They won't last if they can't handle the weather, like rain, blazing sun, and constant UV—important environmental factors to consider.
What about thin film panels? You can use them for more than just roofs. They can stick right to windows, skylights, and curtain walls, letting light through and making power at the same time. We call that Building-Integrated Photovoltaics (BIPV). These solar panels don't just sit on a building; they become a part of it by replacing old materials with new ones that are both useful and good for the environment. Great for cities where roof space fills up quickly.
Best Ways to Install Thin Film Solar Panels
Now that we've talked about the structure, let's talk about the best ways to install thin film solar panels.
Assessment of the Site
Understanding Shade and Sunlight Exposure: Solar pathfinders are tools that help you figure out how much light your solar panels will actually get. Be on the lookout for trees, buildings, or anything else that could block the sun and lower performance.
Finding the best place: Thin film panels can handle diffused light and fit on flat or curved surfaces, but where you put these solar panels is still important. Don't let them shade each other, and think about how to tilt and space them so they get as much sun as possible.
Making the Surface Ready for Panels
Great job! You're ready to put the solar panels up! Next, you need to do this:
Preparing the surface: Once you've chosen the location, getting ready is key. Make sure the area is clear, clean, and dry. There should be no dirt, grease, or dust. Using primers or cleaners from the manufacturer can help solar panels stick better.
Fixing weak spots: Always check for damage before putting it in. Small problems like water stains, rust, and cracks can become big problems later. The surface needs to be smooth and seamless so that the film panels stay in place over time, especially the flexible ones.
Maintenance and Longevity of Thin Film Solar Panels
We've talked about how to put up thin film solar panels, but that's only part of the story. To keep these solar panels working well for a long time, you need to know how to care for them.
Durability Factors for Thin Film Solar Panels:
Thin film solar panels are made to last by being able to handle things like UV rays, moisture, and changes in temperature. Their multilayer design and encapsulation methods help these cells stay safe, but being outside for a long time can still make their efficiency less effective.
Moisture can get into the inner layers of these solar cells, especially in humid or coastal areas. UV rays can also slowly break down adhesives or coatings. Still, a lot of thin film panels keep making power for 20 to 25 years, and their warranties back up their performance. If you install them correctly and take care of them regularly, their lifespan can last even longer.
Inspection Protocols:
Regular inspections are important for keeping thin film solar systems safe and sound both physically and electronically. These checks should include looking for broken adhesive, solar panels that have come apart, and worn surfaces, especially after bad weather like storms. They should happen once a year or twice a year, depending on how the system is set up.
Advanced methods like thermal imaging and electroluminescence testing can find hidden problems in solar cells. In the meantime, a regular inspection plan can help keep things safe, get the most solar energy out of them, keep the warranty in effect, and find problems early.
Most manufacturers include clear instructions in their product manuals on how often and what inspections to do to keep the thin film solar panels working properly.
Applications for Thin Film Solar Panels
We know how to take care of thin film solar panels, but that's just the maintenance. The real question is, where can these solar panels shine? Let's look at some of the applications they could be used for.
Commercial Buildings:
Because they are light and flexible, thin film solar panels are becoming more common on commercial buildings. They can be used on glass fronts, roofs, and even side walls of offices and stores. Building-integrated photovoltaics (BIPV) using solar technology are also being used by big shopping malls and campuses to lower their energy costs, carbon footprint, and environmental impact.
Agriculture Structures:
Thin film solar panels are great for agricultural buildings like greenhouses, barns, and irrigation systems. These film solar cells are great for greenhouse roofs because they are light and only partially transparent, which allows sunlight that is important for growing fruits and vegetables.
Thin film solar panels are also a cheap way to power lights and machines in barns and storage buildings. These solar panels work well in bright light and hot weather. When used in agrivoltaic systems, which combine solar panels and crops, they make land use more efficient and farms more sustainable—excellent applications for solar technology.
Innovative Projects:
Thin film solar technology is opening up all kinds of new ways to get solar energy on the go. For example, solar cells can be built right into electric cars and buses, and portable solar tents can be set up in the middle of a military mission or a disaster relief zone.
What stands out the most? A modular building envelope for agrivoltaics. Imagine thin film panels around the outside of a building that make clean solar energy and power hydroponic gardens inside. The same walls give you food and power. It shows how this solar technology goes far beyond rooftops and finds new applications in cities, farms, and everywhere else.
Exactus Energy: Using Thin Film Technology to Drive Solar Innovation
You have to work with certified structural engineers if you want to put thin film solar panels in a building design. They'll check that everything is safe, built to last, and ready to get the most out of the system.
Exactus Energy is changing the future of solar integration by using thin film solar panels, which are very flexible. These solar panels are great for situations where regular panels won't work because they are light, flexible, and easy to install.
Exactus Energy has a history of carefully adding these film solar panels to buildings with limited roof space or special architectural needs to make sure they get the most solar energy possible without ruining the design. The company is doing this to make energy use more efficient and to make it easier for people to use solar technology.
Thin film solar panels are more than just another box to check. They change the way we think about solar. They are light, flexible, and adaptable, so these solar panels can fit into places that the big, stiff panels could never get to. Thin film fits right in on rooftops that can't hold a lot of weight, glass walls in the middle of a city, and tight spaces where design and function fight for space. These film solar cells are not just tools for getting energy; they are also part of the building.
And they last when you do it right: install them well, check the structure carefully, and keep them up.