Solar device with insulating interconnects

Abstract

The present invention provides a solar device and a method for preparing the solar device. The solar device may include solar cells and an insulating interconnector, wherein the solar cells are configured to form a solar cell string having at least one string terminal, and the insulating interconnector includes two conductive ends and is configured to connect the string terminal to a peripheral circuit of the solar device. The method may include arranging the solar cells to form a solar cell string having at least one string terminal, and arranging an insulating interconnector having two conductive ends to connect the string terminal to a peripheral circuit of the solar device.

Description

Background Art

[0001] The background description provided herein is for the purpose of generally presenting the context of the present disclosure. The inventor's work is neither explicitly nor implicitly admitted to be prior art to the present disclosure within the scope described in this background section and in terms of description that may not otherwise be considered prior art at the time of filing.

[0002] Alternative energy sources are needed to meet the world's growing energy needs. Many geographic regions have abundant solar resources, so these needs can be met in part by providing electricity generated by solar cells. Summary of the Invention

[0003] Aspects of the present disclosure provide a solar device that may include solar cells configured to form a solar cell string having at least one solar cell string terminal and an insulating interconnect including two conductive ends configured to connect the string terminal to a peripheral circuit of the solar device.

[0004] In some embodiments, the insulating interconnect comprises a conductive wire covered by an insulating layer. The insulating interconnect can be arranged in a gap between a solar cell string and another solar cell string. The insulating interconnect can be arranged in a gap between a solar cell string and an edge of a solar device. The insulating interconnect can be stacked on top of a solar cell string. Furthermore, the insulating interconnect can be stacked on top of another insulating interconnect.

[0005] In some embodiments, the solar device may further include a package configured to encapsulate the solar cell string. The package may further include a transparent front sheet and a back sheet. An insulating interconnect may be routed outside the package to connect to peripheral circuitry located outside the package. In one example, the insulating interconnect may be routed outside the package through an opening in the package. The insulating interconnect may also be connected to peripheral circuitry located inside the package.

[0006] In one example, the insulating interconnect has light directing properties to direct light incident on the insulating interconnect toward the solar cell string.

[0007] In one embodiment, the peripheral circuit includes a bypass diode.

[0008] Aspects of the present disclosure provide a method for preparing a solar device. The method may include arranging solar cells to form a solar cell string having at least one string terminal and arranging an insulating interconnect having two conductive ends to connect the string terminal to a peripheral circuit of the solar device.

[0009] In some embodiments, the method may further include packaging the solar cell string and the insulating interconnector into a packaging package. The method may further include forming an opening in the packaging package to route the insulating interconnector outside the packaging package.

[0010] In one embodiment, providing an insulating interconnector having two conductive ends to connect the string terminal to a peripheral circuit of the solar device further includes: coating an insulating varnish layer on the conductive wire to form the insulating interconnector; and forming the two conductive ends of the insulating interconnector.

[0011] In one embodiment, providing an insulating interconnect having two conductive ends to connect the string terminal to a peripheral circuit of the solar device further includes providing the insulating interconnect in a gap between the solar cell string and another solar cell string.

[0012] In one embodiment, providing an insulating interconnect having two conductive ends to connect the string terminal to a peripheral circuit of the solar device further includes providing the insulating interconnect in a gap between the solar cell string and an edge of an enclosure encapsulating the solar cell string and the insulating interconnect.

[0013] In one example, providing an insulating interconnect having two conductive ends to connect the string terminal to the peripheral circuit of the solar device further includes stacking the insulating interconnect on the solar cell string or on top of another insulating interconnect. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various embodiments of the present disclosure, presented as examples, will be described in detail with reference to the following drawings, in which like reference numerals refer to like elements, and in which:

[0015] Figure 1A An exemplary solar device 100 is shown according to an embodiment of the present disclosure;

[0016] Figure 1B shows a cross-sectional view of an exemplary solar cell string 120 (4) according to an embodiment of the present disclosure;

[0017] Figure 1C shows a cross-sectional view of an exemplary insulating interconnect 144 according to an embodiment of the present disclosure;

[0018] Figure 2A An exemplary solar device 200 is shown according to an embodiment of the present disclosure;

[0019] Figure 2B shows a cross-sectional view of an exemplary solar device 200 according to an embodiment of the present disclosure;

[0020] Figure 2C shows an exemplary solar device 290 according to an embodiment of the present disclosure; and

[0021] Figure 3 A flow chart outlining an exemplary process 300 according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0022] Photovoltaic cells (i.e., solar cells) can utilize radiation energy (e.g., light) and convert it into electrical energy. Generally speaking, solar cells are encapsulated in a solar device, and the solar device includes the solar cell and peripheral circuits, such as bypass diodes, current sensors, control circuits, and other circuits suitable for connection to the solar cell. According to aspects of the present disclosure, an insulating interconnect is used in the solar device to connect the solar cell to the peripheral circuit. In some embodiments, the insulating interconnect is formed by a wire covered by an insulating layer.

[0023] Figure 1A An exemplary solar device 100 according to an embodiment of the present disclosure is shown. The solar device 100 includes solar cell strings 120 (1)-(4) of solar cells 10 (n) and peripheral circuits such as electronic devices 181-183. In addition, the solar device 100 includes electrical interconnects such as string connectors 131-134, insulating interconnects 141-146, etc., which conductively couple the solar cell strings 120 (1)-(4) and the peripheral circuits. The solar device 100 can have any suitable shape and configuration. Figure 1A In the example shown, solar device 100 has a rectangular shape. Solar cell strings 120 (1)-(4) are arranged in four parallel rows along a first direction 190, with gaps 171-173 between adjacent rows. Gaps 171-173 can separate adjacent solar cell strings to prevent short circuits between solar cells in adjacent solar cell strings, for example.

[0024] In one embodiment, the solar device 100 may include a packaging package (not shown). For example, the solar cell strings 120 (1)-(4) arranged in a desired configuration and conductively coupled may be packaged in the packaging package. In addition, the packaging package may include a transparent front panel and a back panel. In one embodiment, the solar device 100 may be formed into a laminated structure using a lamination process under heat and pressure conditions. In one embodiment, the electronic devices 181-183 are located inside the packaging package, for example, in a Figure 1A The solar device 100 is shown in the gap 172. During operation, the solar device 100 can provide power to an external load.

[0025] According to aspects of the present disclosure, insulating interconnects 141-146 may be placed in any suitable gaps between solar cells, solar cell strings, etc. Figure 1AIn the example shown, insulating interconnects 141-146 are positioned in gap 172 between solar cell strings 120(2) and 120(3). In one embodiment, each of insulating interconnects 141-146 is configured to have a conductive end and one or more intermediate portions that are insulated from the surrounding environment. In one example, the conductive end of the insulating interconnect can be configured to be a conductive coupling terminal, such as a terminal of an electronic device, a terminal of a solar cell, a terminal of a solar cell string, or the like. In another embodiment, the insulating interconnect can be configured to conductively couple the terminal of the electronic device to the terminal of a solar cell, a solar cell string, or the like through an electrical interconnect such as a string connector. For example, insulating interconnect 141 is configured to conductively couple the terminal of electronic device 181 to the string connector 131, wherein the string connector 131 conductively couples the terminals of solar cell strings 120(1)-(4).

[0026] It may be advantageous to use an insulating interconnect rather than exposed wires such as metal straps. In one example, when an insulating interconnect is used and positioned in gap 172, the width of gap 172 may be reduced. Specifically, when a metal strap is used and positioned in gap 172, a relatively wide gap 172 is required to maintain a safe distance between the metal strap and the adjacent solar cell strings to prevent the metal strap from causing a short circuit in the solar cells of the adjacent solar cell strings. In contrast, using an insulating interconnect may result in a relatively smaller distance due to the insulation provided by the insulating interconnect, thereby reducing the area of ​​the solar device 100 and / or maximizing the area of ​​the solar device for solar energy capture and conversion. Furthermore, due to the insulation, the insulating interconnect may be positioned at any suitable location in the solar device, such as in a gap between solar cell strings or solar cells, in a gap between a solar cell or solar cell string and an edge of the solar device, and so on. In one example, a portion of the insulator interconnect may also be positioned outside the package.

[0027] It should be noted that any suitable circuit configuration, such as a series circuit, a parallel circuit, a combination of series and parallel circuits, etc., can be used in the solar device 100 to optimize the performance of the solar device 100 .

[0028] Figure 1B A cross-sectional view of a solar cell string 120(4) according to an embodiment of the present disclosure is shown. The cross-sectional view of the solar cell string 120(4) is taken along Figure 1AThe BB' section in is obtained. The solar cell string 120 (4) includes solar cells 10 (1)-(12) arranged in a stacked manner, wherein adjacent solar cells partially overlap. Each of the solar cells 10 (1)-(12) may have any suitable structure, shape, material, physical size, etc., and is configured to convert light energy into electrical energy. In a certain example, the solar cell 10 (n) (n is one of 1-12) includes a semiconductor diode structure formed on a silicon substrate. In a certain example, the silicon substrate forms the rear surface of the solar cell 10 (n). In a certain example, the front surface is transparent and is configured to face the light incident direction during operation to receive light energy, and the rear surface is opposite to the front surface. In a certain example, the rear surface is opaque. In another example, the rear surface is transparent and is configured to face the light incident direction during operation to receive light energy, so that the solar cell 10 (n) may be a bifacial solar cell, wherein both the front surface and the rear surface can receive light. It should be noted that when the solar device includes bifacial solar cells, both the front sheet and the back sheet of the package can be transparent.

[0029] In one example, the front surface has front electrical contacts made of one or more conductive materials, such as silver and copper. The front electrical contacts can have any suitable pattern, such as bus bars connected to metal finger structures, etc. The rear surface has rear electrical contacts made of one or more conductive materials, such as aluminum and copper. The rear electrical contacts can have any suitable pattern, such as discrete contact pads, metal contacts that substantially cover the rear surface, etc.

[0030] Depending on the characteristics of the solar cell 10 (n) such as structure and material, the positive terminal may be formed on the front surface or the rear surface. In a certain example, the positive terminal is formed on the front surface through the front electrical contact, and the negative terminal is formed on the rear surface through the rear electrical contact. It should be noted that when the solar cell is connected to an external load during operation, current flows from the positive terminal of the solar cell to the external load. In another example, the positive terminal is formed on the rear surface through the rear electrical contact, and the negative terminal is formed on the front surface through the front electrical contact. In the present disclosure, a solar cell in which a positive terminal is formed on the front surface and a negative terminal is formed on the rear surface is used as an example, and the present disclosure may be appropriately modified to apply to a solar cell in which a negative terminal is formed on the front surface and a positive terminal is formed on the rear surface.

[0031] The solar cell string 120(4) includes solar cells 10(1)-(12) arranged in a row, wherein the two-end solar cells 10(1) and 10(12) are located at two opposite ends of the solar cell string 120(4). Figure 1BIn the embodiment of the present invention, the positive terminal of the solar cell 10(n) is located on the front surface facing the light, and the negative terminal of the solar cell 10(n) is located on the rear surface. Two adjacent solar cells are partially overlapped and electrically coupled in the overlapping area by, for example, conductive pads 12(1)-(11) such as conductive adhesive (ECA). For example, the negative terminal (i.e., rear electrical contact) of the first solar cell 10(n) is conductively coupled to the positive terminal (i.e., front electrical contact) of the second solar cell 10(n+1) via the conductive pad 12(n), where n is an integer from 1 to 11. Therefore, the positive terminal and the negative terminal of the solar cell string 120(4) are located in the corresponding end cells in the solar cell string 120(4), that is, the positive terminal of the solar cell string 120(4) is the positive terminal of the solar cell 10(1), and the negative terminal of the solar cell string 120(4) is the negative terminal of the solar cell 10(12).

[0032] It should be noted that multiple solar cell strings can be connected using any suitable configuration, such as a series configuration, a parallel configuration, or a combination of series and parallel configurations, to optimize the performance of the solar device. Figure 1A , a combination of series and parallel configurations is used by conductively coupling the solar cell strings 120(1)-(4) using string connectors 131-134. For example, the positive terminals of the solar cell strings 120(1)-(4), i.e., the positive terminals on the front surfaces of the solar cells 10(1), 10(21), 10(41), and 10(61), are conductively coupled using string connector 132. Similarly, the negative terminals of the solar cell strings 120(1)-(4), i.e., the negative terminals on the rear surfaces of the solar cells 10(12), 10(32), 10(52), and 10(72), are conductively coupled using string connector 131. In addition, the negative terminals on the rear surfaces of the solar cells 10(4), 10(24), 10(44), and 10(64) are conductively coupled using string connector 134, and the negative terminals on the rear surfaces of the solar cells 10(8), 10(28), 10(48), and 10(68) are conductively coupled using string connector 133. The string connectors 133-134 divide each solar cell string 120(1)-(4) into three sections, each section having four solar cells connected in a series configuration. Therefore, the solar cell strings 120(1)-(4) connected by the string connectors 131-134 are characterized in that the first section 121A-124A forms a first parallel section, the second section 121B-124B forms a second parallel section, and the third section 121C-124C forms a third parallel section; furthermore, the first parallel section, the second parallel section, and the third parallel section are connected in a series configuration. It is noted that the string connector 131 is also the negative terminal of the solar device, and the string connector 132 is also the positive terminal of the solar device. The terminal connectors of the solar device, i.e. Figure 1AThe string connectors 131-132 may be connected to an external load during operation.

[0033] The solar device 100 can be powered during operation, for example, when an external load such as a water heating system is connected between the positive terminal and the negative terminal (not shown) of the solar device 100. In a certain instance, some solar cells, such as a column of solar cells 10(4), 10(24), 10(44), and 10(64), may fail, for example due to shadows blocking some solar cells from receiving light, and thus some solar cells are referred to as failed solar cells. Therefore, when current from a normally operating solar cell flows through the failed solar cell, the resistance of the failed solar cell may increase dramatically, resulting in, for example, the formation of a hot spot in the solar device 100 and a decrease in performance. Therefore, one or more bypass diodes connected in parallel with the failed solar cell may be configured to direct current away from (i.e., bypass) the failed solar cell. In Figure 1A In the embodiment, the electronic devices 181-183 may be three bypass diodes 181-183. For example, when the solar cells 10(1)-(72) operate normally, no current flows through the bypass diodes 181-183 except for leakage current. When the solar cell strings 10(4), 10(24), 10(44), and 10(64) fail, current flows through the bypass diode 183 instead of the first parallel circuit formed by the first segments 121A-124A, thereby ensuring normal operation of the solar device 100.

[0034] Insulating interconnects 141 - 146 may have any suitable structure, material, shape, size, etc. to conductively couple different components of a solar device, such as electronics and solar cells, or to conductively couple one solar cell to another solar cell. Figure 1C A cross-sectional view of an exemplary insulating interconnect 144 according to an embodiment of the present disclosure is shown. The cross-sectional view of the insulating interconnect 144 is taken along Figure 1A Insulating interconnect 144 includes conductive wire 144A covered by an electrically insulating layer or insulating layer 144B. In one example, insulating interconnect 144 may be an insulated conductive tape comprising a flexible metal tape coated with one or more layers of insulating material. In another example, insulating interconnect 144 may comprise a plurality of insulated metal wires bundled together.

[0035] The conductor 144A may have any suitable cross-sectional shape, such as a rectangular shape including a copper sheet ( Figure 1C ), circular, irregular, etc. Furthermore, the conductive wire 144A may include multiple components, such as multiple conductive strings extending parallel to each other. The conductive wire 144A may also include multiple layers. The conductive wire 144A may be made of any suitable conductive material, such as copper and aluminum, or a combination of suitable materials, such as alloys and conductive composite materials.

[0036] Insulating layer 144B may have any suitable cross-sectional shape, such as a rectangular ( Figure 1C ), circular, irregular, etc. Insulation layer 144B may also include multiple sub-layers. Insulation layer 144B may completely or partially cover conductive line 144A. Insulation layer 144B may be made of any suitable insulating material, any combination of suitable insulating materials, etc.

[0037] The insulating interconnect may have suitable light-directing properties to direct light incident on the insulating interconnect toward the solar cell or solar cell string. In one embodiment, the insulating interconnect may include suitable light-directing materials and structures, such as microstructures, so that light incident on the insulating interconnect can be directed toward the solar cell or solar cell string and subsequently converted into electrical energy. Furthermore, the physical configuration of the insulating interconnect, such as its position and orientation, can be adjusted accordingly to direct more light from the insulating interconnect toward the solar cell or solar cell string.

[0038] In some embodiments, the electrical terminals (positive and negative terminals) of the solar cell are formed on the back surface (e.g., substrate) of the solar cell, and such solar cells are referred to as back-contact solar cells. It should be noted that in some embodiments, back-contact solar cells are used in the solar device 100. In one example, an interdigitated back-contact solar cell (IBC) is a back-contact solar cell. In one embodiment, when the solar cells 10(1)-(72) are back-contact solar cells, the back-contact solar cells may be formed on the back surface (e.g., substrate) of the solar cell. Figures 1A-1B In one embodiment, the solar cells 10(1)-(72) may be arranged side by side in a non-overlapping manner, which is different from Figure 1B In addition, electrical connections between adjacent back contact solar cells can be formed on the rear surface. Figure 1A Different from the configuration in FIG, string connector 132 can contact the rear surface of solar cells 10(1), 10(21), 10(41) and 10(61). According to aspects of the present disclosure, the insulating interconnect in the solar device can also be used to connect the back-contact solar cell to a peripheral circuit having an electronic device. In addition, when the solar device includes one or more solar cells, one or more solar cell strings, etc., the insulating interconnect in the solar device can also be used to connect the solar cell to a peripheral circuit having an electronic device. The solar cell string can be a stacked solar cell string, a solar cell string including non-overlapping solar cells, etc.

[0039] Insulated interconnects in solar devices may also be stacked onto one or more solar cells or one or more strings of solar cells. Figure 2AAn exemplary solar device 200 according to an embodiment of the present disclosure is shown. The solar device 200 includes solar cells 210(1)-(18) and peripheral circuitry such as electronic devices 265. The solar device 200 also includes electrical interconnects such as cell connectors 220(1)-(12) that conductively couple adjacent solar cells 210(1)-(18) in the same column, bus bars 233-237 that conductively couple solar cells of adjacent columns, end connectors 231-232 of the solar device 200, and insulating interconnects 241-242 that conductively couple the terminal connectors 231-232 to peripheral circuitry such as electronic devices 265. In one example, the solar cells 210(1)-(18) are back-contact solar cells. Figure 2A The rear surface of solar cells 210 (1) - (18) is shown. Cell connectors 220 (1) - (12), bus bars 233 - 237 and terminal connectors 231 - 232 are connected to the solar cells on the rear surface.

[0040] Solar device 200 may have any suitable shape and configuration. Figure 2A In the example shown, the solar device 200 has a rectangular shape. The solar cells 210 (1)-(18) are arranged in three parallel rows along a first direction 285 and six parallel columns along a second direction 286. In one example, the first direction 285 is perpendicular to the second direction 286. The solar cells 210 (1)-(18) are connected in series to form a series circuit. During operation, the series circuit is connected to an external load via, for example, the negative terminal of the solar device (i.e., terminal connector 231) and the positive terminal of the solar device (i.e., terminal connector 232). Thus, current flows from the negative terminal to the solar cell 210 (1), then from 210 (n) to 210 (n+1), where n is an integer from 1 to 17, then from 210 (18) to the positive terminal, and from the positive terminal to the external load.

[0041] Alternatively, the solar cells 210(1)-(18) may be arranged into six solar cell strings corresponding to six parallel columns in the second direction 286 using the cell connectors 220(1)-(12). For example, the solar cell string includes the solar cells 210(1)-(3). Adjacent solar cell strings may then be appropriately connected via bus bars 233-237 to form Figure 2A The series circuit shown.

[0042] Figure 2B A cross-sectional view of an exemplary solar device 200 according to an embodiment of the present disclosure is shown. Figure 2AThe BB' section of the first row is obtained, and the first row includes solar cells 210(1), 210(6), 210(7), 210(12), 210(13) and 210(18). In one embodiment, the solar device 200 includes a packaging package 250 that encapsulates the solar cells 210(1)-(18). In addition, the packaging package may include a transparent front sheet 251, an encapsulation material 252 and a back sheet 253. In one example, the solar device 200 can be formed into a laminated structure using a lamination process under heat and pressure conditions.

[0043] exist Figures 2A-2B In the example shown, the electronic device 265 connected between the terminal connectors 231-232 is connected in parallel with the series circuit. In one example, the electronic device 265 is a bypass diode. In other examples, the electronic device 265 can be a DC / AC inverter, a DC / DC module power optimizer, a "smart" switch, or any suitable combination thereof. The electronic device 265 can be placed inside or outside the package 250. Figure 2B In the example shown, the electronic device 265 is located outside the package 250. In order to connect the electronic device 265 located outside the package 250 to the terminal connectors 231-232 inside the package 250, the insulating interconnects 241-242 are routed outside the package 250, for example, through the openings 243-244 in the package 250. Figure 2B In the example shown, the openings 243-244 are located on the back panel 253. Generally speaking, the openings may be located at any suitable location in the package, such as on the front panel, the back panel, an edge of the package, etc.

[0044] According to aspects of the present disclosure, insulating interconnects 241-242 are stacked on the first row of solar cells 210(1), 210(6), 210(7), 210(12), 210(13), and 210(18). In one embodiment, a gap 281 between the insulating interconnects 241-242 and the rear surface of the first row of solar cells may be maintained as follows: Figure 2B In another example, the insulating interconnects 241 - 242 can be in physical contact with the rear surface of the solar cell, and the gap 281 can be set to zero due to the insulating effect provided by the insulating layer of the insulating interconnects 241 - 242 .

[0045] In certain embodiments, insulating interconnects such as insulating interconnects 241-242 can be configured to conductively couple terminals of an electronic device to terminals of a solar cell, a solar cell string, and the like. Furthermore, insulating interconnects such as insulating interconnects 241-242 can be routed from the interior of the package to the exterior and conductively coupled to peripheral circuitry, including electronic devices outside the package. In certain examples, the insulating interconnects can be routed from the interior of the package to the exterior via one or more openings in the package, such as one or more openings in a front panel, a back panel, an edge of the package, and the like.

[0046] In another embodiment, insulating interconnects such as insulating interconnects 241-242 can be configured to conductively couple terminals of an electronic device to terminals of a solar cell, solar cell string, etc. via electrical interconnects such as terminal connectors 231-232. For example, insulating interconnect 241 is configured to conductively couple terminals of electronic device 265 to terminal connector 231, wherein terminal connector 231 is conductively coupled to solar cell 210(1).

[0047] In certain embodiments, an insulating interconnect may also be stacked on top of another insulating interconnect in a solar device. Figure 2C An exemplary solar device 290 according to an embodiment of the present disclosure is shown. The solar device 290 includes solar cells 210 (1)-(18) and peripheral circuitry (not shown) electrically connected using insulating interconnects 291-294. The arrangement and connection of the solar cells 210 (1)-(18) are similar to those of FIG. Figure 2A The arrangement and connections of the solar device 200 shown in FIG. 2 are the same, so for the sake of clarity, the description of the solar cells 210 (1)-(18), the cell connectors 220 (1)-(12), the bus bars 233-237, and the terminal connectors 231-232 of the solar device 290 are omitted. In one embodiment, the solar cells 210 (1)-(18) are back contact solar cells, and Figure 2C The rear surfaces of solar cells 210 ( 1 )-( 18 ) are shown.

[0048] The insulating interconnects 291-294 can conductively couple the solar cell to a peripheral circuit. For example, the insulating interconnect 291 having a first conductive end 291(1) and a second conductive end 291(2) can conductively couple the terminal connector 231 to a terminal (not shown) in the peripheral circuit. Figure 2C, first conductive end 291(1) is conductively coupled to terminal connector 231, and second conductive end 291(2) is conductively coupled to a terminal in a peripheral circuit. Similarly, insulating interconnects 292-294 can conductively couple bus bar 234, bus bar 236, and terminal connector 232 to corresponding terminals (not shown) in a peripheral circuit using respective first conductive ends 292(1)-294(1) and second conductive ends 292(2)-294(2).

[0049] According to aspects of the present disclosure, insulating interconnect 292 is stacked on insulating interconnect 291 to obtain overlap region 295. Additionally, insulating interconnect 293 is stacked on insulating interconnect 294 to obtain overlap region 296. In one embodiment, stacking an insulating interconnect on another insulating interconnect can reduce the area of ​​the solar device and / or maximize the area of ​​the solar device used for solar energy capture and conversion. The second conductive ends 291 (2)-294 (2) can be electrically coupled to any suitable electronic device in the peripheral circuit, such as a bypass diode, a DC / AC inverter, a DC / DC module power optimizer, a "smart" switch, and any suitable combination thereof. Additionally, a portion of one or more of the insulating interconnects 291-294 can be located outside the package encapsulating the solar device 290. A portion of the overlap region 295-296 can be located inside or outside the package. The insulating interconnects 291-294 can have any suitable shape and size and can be located at any suitable location in the solar device 290.

[0050] exist Figures 2A-2C In the example shown, the solar cell is a back-contact solar cell. In another example, the solar cell in the solar device 200 and 290 can be any suitable solar cell, such as a solar cell having a front electrical contact on the front surface and a rear electrical contact on the rear surface, including a bifacial solar cell. Therefore, the position and connection of the cell connectors 210 (1)-(18), bus bars 233-237 and terminal connectors 231-232 can be modified accordingly. For example, the cell connector 220 (1) can connect the positive terminal on the front surface of the solar cell 210 (1) to the negative terminal on the rear surface of the solar cell 210 (2); the bus bar 233 can connect the positive terminal on the front surface of the solar cell 210 (3) to the negative terminal on the rear surface of the solar cell 210 (4), and the positive terminal of the module circuit (i.e., the terminal connector 232) can be connected to the front electrical contact of the solar cell 210 (18). Insulating interconnects 241-242 may also be stacked above the first row of solar cells 210(1), 210(6), 210(7), 210(12), 210(13), and 210(18). However, insulating interconnect 242 connects to terminal connector 232 located on the front surface of solar cell 210(18).

[0051] According to aspects of the present disclosure, an insulating interconnect having two conductive ends may be used to make any suitable electrical connection in a solar device, such as connecting peripheral circuits including electronic devices to solar cells ( Figure 1A 、 Figure 2A and Figure 2C ), connecting solar cells or solar cell strings, connecting electronic devices to peripheral circuits, etc. The insulating interconnects can be connected to the terminals of any suitable solar cell, such as a solar cell having a front electrical contact on the front surface and a rear electrical contact on the rear surface ( Figures 1A-1B ), back contact solar cells ( Figures 2A-2C ), double-sided solar cells, etc.

[0052] According to aspects of the present disclosure, insulating interconnects may be employed in any suitable solar device. A solar device may be comprised of solar cells ( Figure 2A and Figure 2C ), solar cell string ( Figure 1A ) etc. The solar device may include any suitable number of solar cells, any suitable number of solar cell strings, and peripheral circuits, the peripheral circuits including any suitable electronic devices such as bypass diodes, current sensors, control circuits, etc. In addition, the solar cell string may include any suitable number of solar cells connected using any suitable methods and materials. The solar cell string may be in a stacked manner ( Figure 1A ), formed in a non-overlapping manner (such as a solar cell string, including Figure 2B In addition, the solar cell device may include any suitable circuit configuration, such as a series circuit ( Figure 2A ), parallel circuits, series and parallel combination circuits ( Figure 1A )etc.

[0053] According to aspects of the present disclosure, the insulating interconnect may be located at the solar cell ( Figure 1A ) between solar cell strings ( Figure 1A ), between solar cells or solar cell strings and the edge of a solar device or package, etc. In another embodiment, the insulating interconnects may be stacked between solar cells ( Figures 2A-2B ), solar cell strings, etc. In one embodiment, a gap may be provided between the insulating interconnect and the solar cell or solar cell string. In another embodiment, the insulating interconnects may be stacked on top of each other ( Figure 2CIn one embodiment, gaps may be provided between stacked insulating interconnects. Furthermore, the position, orientation, and the like of the insulating interconnects may also be determined based on the light-directing properties of the insulating interconnects. For example, the position and orientation of the insulating interconnects may be optimized so that more light incident on the insulating interconnects is directed toward the solar cells and solar cell strings.

[0054] According to aspects of the present disclosure, the insulating interconnect can be routed from the interior of the package to the exterior of the package, for example, when the insulating interconnect is configured to connect the solar cell inside the package to the peripheral circuits of the electronic device ( Figure 2B ). In addition, the electronic devices outside the package can be located in a junction box outside the package. In one embodiment, the insulating interconnects can be connected to the terminals of the junction box, and the terminals of the junction box can be connected to the electronic devices. The insulating interconnects can be routed from the interior of the package to the exterior through an opening in the package. The opening can be located at any suitable location in the package, such as the front panel, back panel, edge of the package, etc.

[0055] In a certain embodiment, the solar cell may be a bifacial solar cell, wherein both the front surface and the rear surface receive light. In a certain example, the rear electrical contact of the rear surface of the bifacial solar cell may be similar to or the same as the front electrical contact of the front surface of the bifacial solar cell. In addition, a bifacial solar device may be formed using a bifacial solar cell and a packaging package having a transparent front plate and a transparent back plate, such as a piece of glass. According to aspects of the present disclosure, an insulating interconnect may be used in the bifacial solar device. In a certain example, an insulating interconnect may be used to connect the solar cell or solar cell string inside the bifacial solar device to peripheral circuits outside the bifacial solar device, including electronic devices, via the front plate, back plate, etc. of the packaging package of the bifacial solar device. Figure 3 A flow chart outlining an exemplary process 300 according to an embodiment of the present disclosure is shown. In one example, the process 300 can be performed to form a solar device including an insulating interconnect, such as Figure 1A The solar device 100, Figure 2A Solar device 200 and Figure 2C Solar device 290 in.

[0056] The process starts at S301. In S301, various components of the solar device are formed, such as a plurality of solar cells, electronic devices, insulating interconnects, and the like. In one embodiment, a string of solar cells may be formed. In one embodiment, other components may also be formed, such as components for use in a package, including a transparent front panel, a back panel, and the like. The transparent front panel may be made of glass. The back panel may be made of glass, polymer, and the like. In one embodiment, one or more openings may be preformed on the transparent front panel, back panel, and the like to route insulating interconnects from the inside to the outside of the package, which includes the transparent front panel, back panel, and the like. For example, a preformed opening may be formed on the back panel 253. Figure 2B Then, the process goes to S310.

[0057] In S310, a plurality of solar cells are arranged and conductively coupled. In one embodiment, a subset of the plurality of solar cells is used, such as Figure 1A As shown, solar cell strings 120(1)-(4) are pre-formed into one or more solar cell strings in a desired configuration. The solar cell strings are then arranged and conductively coupled. For example, solar cell strings 120(1)-(4) are conductively coupled using string connectors 131-134 to form series and parallel combination circuits. Solar cell strings such as string connectors 131-134 can be conductively coupled using flexible metal strips, such as thin copper sheets having a suitable pattern, and can be bonded to the ECA applied to the solar cells.

[0058] In another example, a plurality of solar cells such as solar cells 210(1)-(18) may be arranged in a desired configuration and conductively coupled, such as Figure 2A and Figure 2C The series circuit shown.

[0059] Furthermore, a plurality of solar cells can be arranged in a desired configuration and conductively coupled to a transparent front sheet, such as a piece of glass, a back sheet, such as a polymer sheet, etc., of a solar device. In one example, bifacial solar cells can be used in a solar device, and the back sheet can be a transparent glass sheet. Figure 2A In the example shown, solar cells 210 ( n ) are arranged and conductively coupled to a backsheet 253 of the solar device 200 .

[0060] In S320, one or more insulating interconnects are arranged relative to the plurality of solar cells. In a certain embodiment, each insulating interconnect may include a middle portion that is insulated from the surrounding environment and is sandwiched between a first conductive end and a second conductive end. In a certain embodiment, the insulating interconnect may be prefabricated to have a desired size, such as a thickness ranging from 50 microns to 250 microns, a width ranging from 2 millimeters (mm) to 10 millimeters, and a desired electrical conductivity, for example, 58.5 Siemens / meter (m) for copper and 36.9 Siemens / meter for aluminum. In a certain instance, the insulating interconnect is formed by coating an insulating varnish layer on a wire. In addition, the two conductive ends of the insulating interconnect may be exposed and processed so as to be conductively coupled to a cell connector, a string connector, a bus bar, a terminal connector, a terminal of a solar cell or a solar cell string, a terminal of an electronic device in a peripheral circuit, and the like.

[0061] One or more insulating interconnects may be arranged relative to a solar cell string formed of a plurality of solar cells or a plurality of solar cells. Generally speaking, the insulating interconnects may be arranged at any suitable location in the solar device, such as in a gap between adjacent solar cells or solar cell strings, in a gap between a solar cell or solar cell string and an edge of the solar device, on a solar cell or solar cell string, etc. Figure 1A In the example shown, the insulating interconnects 141-146 are arranged in the gaps 172 between the solar cell strings 120(2)-(3). Figure 1A , the first conductive end of each of the insulating interconnects 141-146 is connected to a terminal of the solar cell via one of the string connectors 131-134. In one embodiment, the first conductive end of each of the insulating interconnects 141-146 can be welded or bonded using pressure and heat to positions 175-178 of the string connectors 131-134, respectively. In addition, insulating interconnects such as the insulating interconnects 141-146, solar cells, or solar cell strings such as solar cell strings 120(2)-(3) can be positioned and retained using, for example, adhesive tape.

[0062] exist Figure 2A In another example shown, insulating interconnects 241-242 are arranged relative to solar cells 210(1)-(18) and stacked above a first row of solar cells 210(1), 210(6), 210(7), 210(12), 210(13), and 210(18). Figure 2A, the first conductive end of each of the insulating interconnects 241-242 is connected to a terminal of the solar cell via one of the terminal connectors 231-232. In one embodiment, the first conductive end of each of the insulating interconnects 241-242 can be welded or bonded using pressure and heat to the terminal connectors 231-232 at positions 245-246, respectively. In addition, a gap 281 can be provided and maintained between the insulating interconnects 231-232 and the solar cells 210(1), 210(6), 210(7), 210(12), 210(13), and 210(18), for example, by inserting an encapsulating material.

[0063] In S330, at least one conductive end of the one or more insulating interconnects is conductively coupled to a terminal of an electronic device in a peripheral circuit of the solar device. Figure 1A , the second conductive end of each of the insulating interconnects 141-146 is connected to a terminal of one of the electronic devices 181-183. Figures 2A-2B , a second conductive end of each of the insulating interconnects 241 - 242 is connected to a corresponding terminal of the electronic device 265 .

[0064] In one embodiment, a package including a transparent front sheet and a back sheet can be configured to encapsulate a plurality of solar cells and at least a portion of one or more insulating interconnects. Subsequently, a lamination process can be used under heat and pressure to form a cured laminate structure.

[0065] When a peripheral circuit such as an electronic device is located within the package, the conductive end of the insulating interconnect and the terminal of the electronic device can be conductively coupled by, for example, soldering the conductive end of the insulating interconnect and the terminal of the electronic device. In another example, the conductive end of the insulating interconnect and the terminal of the electronic device can also be electrically bonded by applying pressure and heat.

[0066] When at least one electronic device of the peripheral circuit is outside the package, at least one insulating interconnect can be routed outside the package via at least one opening on the package, such as the opening on the front plate, back plate or edge of the package as described above. Therefore, as described in S301, one or more openings are formed in the package. Figure 2A In the example shown, the insulating interconnects 241 and 242 are routed outside the package via the openings 243 - 244 . Furthermore, in S320 , the insulating interconnects may be aligned relative to the at least one opening.

[0067] In one example, the conductive ends of the insulating interconnects can be connected via external cables such as Figure 2BExternal cables 263 and 264 are connected to terminals of the electronic device. In one embodiment, the peripheral circuitry including the electronic device may be placed in a junction box having terminal block connectors that connect the external cables to the electronic device. Subsequently, the solar device may be connected to and power an external load during operation. Process 300 then proceeds to S399 and terminates.

[0068] Although aspects of the present disclosure have been described with reference to specific embodiments of the invention presented as examples, these examples may be replaced, modified, and varied. Therefore, the embodiments described herein are intended to be illustrative and not restrictive. Changes may be made without departing from the scope of the claims set forth below.

Claims

1. A solar energy device comprising: a plurality of solar cells configured to form a solar cell string, the solar cell string comprising at least a first solar cell string and a second solar cell string arranged in two parallel rows; a plurality of string connectors extending perpendicularly to the first solar cell string and the second solar cell string across a gap between the first solar cell string and the second solar cell string and configured to electrically connect the first solar cell string and the second solar cell string in parallel, the plurality of string connectors comprising at least a first string connector and a second string connector, the first string connector being disposed in the gap between the first solar cell string and the second solar cell string and configured to connect a first end of the first solar cell string and a first end of the second solar cell string, the second string connector being disposed in the gap between the first solar cell string and the second solar cell string and configured to connect a second end of the first solar cell string and a second end of the second solar cell string; a plurality of insulating interconnects, each of the insulating interconnects comprising a conductor having two conductive ends and a middle portion insulated from the surrounding environment, the plurality of insulating interconnects being parallel to the first solar cell string and the second solar cell string, the insulating interconnects being configured to connect a peripheral circuit disposed at different positions within a gap between the first solar cell string and the second solar cell string to a corresponding one of the plurality of string connectors, wherein the plurality of insulating interconnects have no exposed conductors; wherein the plurality of insulating interconnects are disposed within a gap between the first solar cell string and the second solar cell string and between the first string connector and the second string connector; and In each of the plurality of solar cell strings, adjacent solar cells partially overlap to form a stacked structure.

2. The solar device of claim 1, wherein the plurality of insulating interconnects are stacked above the solar cell string. 3 . The solar device of claim 1 , wherein the plurality of insulating interconnects are stacked on another insulating interconnect.

4. The solar device according to claim 1, further comprising: A packaging package is configured to package a plurality of solar cell strings.

5. The solar device according to claim 4, wherein the packaging package further comprises: Transparent front panel; and Back panel. 6 . The solar device of claim 4 , wherein the plurality of insulating interconnects are routed outside the package to connect the peripheral circuit outside the package.

7. The solar device of claim 4, wherein the plurality of insulating interconnects are connected to the peripheral circuitry within the package.

8. The solar device of claim 6, wherein the plurality of insulating interconnects are routed outside the package via openings in the package.

9. The solar device of claim 1, wherein the plurality of insulating interconnects have light directing properties to direct light incident on the insulating interconnects toward the solar cell string.

10. The solar device of claim 1, wherein the peripheral circuit comprises a bypass diode.

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