The challenge of frameless panels

Imagine an elegant, modern house with a roof that looks like it is made of a uniform material and at the same time produces electricity. No visible frames, no metal borders interfering with its clean line. Such a vision remained in the realm of dreams for a long time, as attempts to create frameless panels usually ended in compromises in durability or safety.

Traditional photovoltaic panels use aluminum frames for several reasons. First of all, they protect the delicate edges of the glass from mechanical damage during transportation and installation. The frame also ensures the rigidity of the entire structure and protects against moisture penetration between the layers of the panel. However, these same frames create a natural place for dirt and debris to accumulate. In standard roof installations, you can regularly observe the characteristic dark lines along the frames - this is the result of a backlog of dust and other contaminants, which not only worsen the aesthetics, but can also affect the performance of the entire system.

The problem becomes even more pronounced in the case of building-integrated photovoltaic (BIPV) systems. In the traditional approach, frames not only spoil the appearance of the roof, but also complicate the installation process and can create potential leak sites. Any joint between the frame and the roof surface requires additional sealing, and the multiplicity of such points increases the risk of failure in the future.

Moreover, metal frames can contribute to the formation of microcracks in photovoltaic cells. When the panel heats up (and temperatures on the roof on sunny days can exceed 70°C), thermal expansion of glass and metal occurs. Since these materials have different coefficients of thermal expansion, stresses arise that in the long run can lead to damage.

Attempts to create frameless panels were made many times, but problems always arose. Inadequately protected glass edges were easily damaged. The lack of a frame meant less rigidity of the structure, which increased the risk of cracks during assembly. There were also problems with sealing and durability of the joints. As a result, most manufacturers stayed with a proven, though not ideal, solution with aluminum frames.

These challenges were particularly relevant in the context of roofs integrated with photovoltaics. After all, the roof is not only a source of energy - it is, first of all, the protection of the building from weather conditions. Each solution therefore had to fulfill a dual role: to ensure efficient energy production and to guarantee tightness for decades. Therefore, a completely new approach to the design of photovoltaic panels was needed.

EdgeFlow technology in practice

EdgeFlow Design technology is a completely new approach to photovoltaic panel construction that eliminates the need for traditional aluminum frames. This is the result of many years of research and cooperation with experts from the architectural glass industry and the electronics industry.

Let's start with how a frameless panel is made. It all starts with specially tempered 4mm thick solar glass. This is no ordinary glass - it is designed specifically for photovoltaic applications, with adequate light transmittance and mechanical strength. In traditional panel production, the glass was simply cut and mounted in a frame. With EdgeFlow technology, each slab goes through an advanced edge processing process.

The key element is the precise processing of the edges of the glass. In our factory in Poland, we installed a robotic edge grinding line that works with an accuracy of 0.1 mm. This is an accuracy unattainable with manual processing. Each edge is sanded at a specially calculated angle, which ensures optimal water drainage. It's a bit like in modern smartphones - there, too, the edges are precisely chamfered to improve not only the appearance, but also the ergonomics.

After grinding, the edges go through the process of thermal hardening. This is a key step that increases the strength of glass up to five times compared to untempered glass. This process is computer controlled, with precise monitoring of temperature and cooling time. It is during hardening that the characteristic structure of the glass is formed, which means that even in the event of damage it breaks into small, blunt pieces that do not pose a threat.

The next step is to apply a special protective coating to the edges. This layer not only protects the glass from mechanical damage, but also creates a moisture barrier. The coating is applied under strictly controlled conditions, at the right temperature and humidity. This process is somewhat reminiscent of the technologies used in the manufacture of automotive glass, where the edges must be perfectly protected from weather conditions.

The innovation of EdgeFlow Design also lies in the special shaping of the edge profile. Instead of a straight cut, the edge has a gently rounded profile that makes it easier for water to drain. This solution was inspired by research on aerodynamics - similar profiles are used in aviation to control air flow. In our case, it's all about controlling the flow of water - raindrops do not stop at the edges, but flow smoothly, taking debris with them.

EdgeFlow Design technology is not just glass processing itself. It is also a system of special fastenings and seals that allow the panel to be securely integrated into the roofing. Each panel is equipped with precisely spaced mounting points that distribute loads evenly over the entire surface. This eliminates the risk of point stresses that could lead to damage.

All this makes the panels with EdgeFlow Design technology not only aesthetic, but also extremely durable and safe. Each stage of production is controlled by computer systems and subjected to rigorous quality testing. The result is a product that combines the elegance of architectural glass with the durability of professional photovoltaic systems.

Practical benefits and the future of technology

The introduction of EdgeFlow Design technology is completely changing the way we view solar roofs. Let's see what concrete benefits this solution brings and how it works in everyday use.

First of all, the roof with EdgeFlow Design panels simply looks better. The absence of metal frames makes the whole a uniform, elegant surface. It is no longer a roof “with attached panels” - it is an architecturally coherent whole. You can see this difference especially well in sunlight, when characteristic shadows and reflections from aluminum frames appear on traditional installations. With EdgeFlow Design, the light moves smoothly over the roof surface, not disturbed by any structural elements.

Interestingly, the lack of frames also translates into higher system performance. Traditional aluminum frames create places where dirt and moisture accumulate. Over time, these contaminants can partially obscure photovoltaic cells, reducing their efficiency. With EdgeFlow Design technology, rainwater flows freely over the surface of the panels, taking debris with it. This natural self-cleaning ensures that the panels retain their optimum performance for longer.

Homeowners with EdgeFlow Design especially appreciate the ease of keeping their roof clean. When there is a need to wash the panels, the process is much simpler than with traditional installations. There are no hard-to-reach crevices and nooks where dirt would accumulate. It is enough to rinse the surface with water - the absence of frames means no places where debris could linger.

The EdgeFlow Design technology is also perfect for harsh weather conditions. During heavy rainfall, water quickly drains from the roof surface, without forming stagoin. In winter, snow slides off a smooth surface more easily, reducing the load on the structure. This is especially important in the context of safety - the even sliding of snow prevents the formation of dangerous snow overhangs.

Let's look at the example of a detached house in the mountains, where the EdgeFlow Design system has passed a real endurance test. During an extremely snowy winter, significant amounts of snow accumulated on the roof. With traditional framed panels, snow often stops at the metal edges, creating irregular snowdrifts. On the roof with the EdgeFlow Design system, the snow slid evenly, without creating point loads on the structure.

The future of EdgeFlow Design technology looks promising. We are currently working on further enhancements that will further enhance the durability and performance of the system. One of the directions of development is the use of new hydrophobic coatings, which will further improve the self-cleaning properties of the panels. We are also conducting research on the integration of the system with intelligent sensors monitoring the technical condition of the roof.

Moreover, EdgeFlow Design technology opens up new possibilities in terms of customizing the appearance of the roof. The absence of aluminum frames allows the use of different colors and surface finishes of the panels more freely. We already offer the ability to match the color of the panels to traditional building materials, and in the future we plan to introduce even more customization options.

EdgeFlow Design is not just another technical innovation - it is a change in the approach to solar roof design. We show that modern photovoltaic technology can be not only efficient, but also beautiful and practical in everyday use. This is a step towards a future in which renewable energy will be a natural part of the architecture of our homes.

‍