Photovoltaic module
By designing four cell arrays in the photovoltaic module and rationally setting the connection between the bypass diode and the cell array, the problem of high hot spot risk under multi-segmentation process was solved, and a high-efficiency and high-reliability photovoltaic module design was achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- YOURSUN NEW ENERGY DEVELOPMENT (HANGZHOU) CO LTD
- Filing Date
- 2025-04-10
- Publication Date
- 2026-04-21
AI Technical Summary
While improving the efficiency of existing photovoltaic modules, the risk of hot spots is high, especially under multi-segmentation technology, the increased number of cells leads to a greater risk of hot spots and poses a safety hazard.
The system employs a four-cell array structure, with each array consisting of three cells of the same length connected in parallel. By rationally configuring the connection relationship between the bypass diodes and the cell arrays, the length of the cell string protected by each bypass diode does not exceed 26-32 cells. Combined with the use of tin-plated copper busbars, the system's resistance to hot spots is improved.
It improves the output power of photovoltaic modules, has strong compatibility, and features high power, high efficiency, and high reliability. It effectively reduces the risk of hot spots and improves safety.
Smart Images
Figure CN224154563U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of photovoltaic technology, and in particular to a photovoltaic module. Background Technology
[0002] Conventional photovoltaic modules use solder ribbons to connect the cells in series. To ensure the safety of hot spots under external shading, several bypass protection diodes need to be installed on the cell string. Usually, the number of cells in the cell string protected by each bypass protection diode does not exceed 25-30. Otherwise, under certain shading conditions, high-temperature hot spots can easily form, causing the photovoltaic panel to crack and be damaged, or even causing a fire.
[0003] In recent years, mainstream photovoltaic modules in the industry have adopted half-cell technology, typically using a series connection of half-cells followed by parallel connection of the upper and lower sections. For example, the module is divided into upper and lower sections, with all cells in each section connected in series, and then connected in parallel. The circuit includes three bypass diodes, each protecting one-third of the cells. Specifically, for a 78-cell module, 78 half-cells are connected in series at both the upper and lower sections, with each bypass diode protecting 26 half-cells. When each bypass diode protects more than 26 cells, it leads to a significant risk of hot spots, creating a safety hazard.
[0004] To further improve module power, a multi-segmentation process can be used, cutting the solar cells into three or four segments. The smaller the area of a single series-connected solar cell, the lower the current and the lower the internal resistance loss. With a fixed input power, the lower the internal resistance loss power, the greater the maximum usable output power, thereby increasing the module's output power. While multi-segmentation can increase module power, it also significantly increases the number of series-connected solar cells without changing the circuit structure, thus increasing the risk of hot spots. Utility Model Content
[0005] To address the problem of high hot spot risk when improving the efficiency of photovoltaic modules in existing technologies, this utility model proposes a photovoltaic module.
[0006] The specific technical solution is as follows:
[0007] A photovoltaic module includes: four cell arrays, the four cell arrays being arranged adjacent to each other in both the horizontal and vertical directions, each cell array being composed of three cell strings of the same length connected in parallel, each cell string being composed of multiple cell strings segmented and connected in series, a bypass diode being provided next to each of the four cell arrays, and the four cell arrays being connected in series sequentially.
[0008] Furthermore, the battery string is divided into slices of one of the following: two slices, three slices, or four slices.
[0009] Furthermore, the number of battery string slices is 24 to 30.
[0010] Furthermore, the number of segments in the battery string is less than 24.
[0011] Furthermore, the spacing between adjacent battery string segments in the battery string is -2 to 2 mm.
[0012] Furthermore, the battery strings in the battery array are connected by busbars, which are tin-plated copper busbars.
[0013] Furthermore, the busbar is disposed between adjacent battery arrays arranged longitudinally, or on the back of the battery array.
[0014] Furthermore, each of the battery arrays is provided with a bypass diode.
[0015] Furthermore, the total number of battery string slices in adjacent battery arrays arranged longitudinally is less than 24, and adjacent battery arrays arranged longitudinally share a single bypass diode.
[0016] Furthermore, the total number of battery string slices in the adjacent battery arrays arranged horizontally is less than 24, and the adjacent battery arrays arranged horizontally share a single bypass diode.
[0017] The above technical solution has the following advantages or technical effects:
[0018] 1. This utility model improves the output power of photovoltaic modules through multi-segmentation technology, and by reasonably setting the connection relationship between bypass diodes and cell arrays, the length of the cell string protected by each bypass diode does not exceed 26-32 cells, which has excellent anti-hot spot effect.
[0019] 2. The structure of the photovoltaic module in this utility model has strong compatibility and can be applied to various multi-segmented solar cells, giving full play to the characteristics of high power, high efficiency and high reliability. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the structure of one embodiment of the present utility model;
[0021] Figure 2 This is a schematic diagram of the structure of one embodiment of the present utility model;
[0022] Figure 3 This is a structural schematic diagram of one embodiment of the present invention. Detailed Implementation
[0023] To make the technical solution of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0024] Example 1
[0025] A photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions, the four cell arrays being located in the same plane, each cell array consisting of three cell strings of equal length connected in parallel, and a bypass diode disposed next to each of the four cell arrays. The bypass diode is used to protect the cell arrays from shading or hot spot conditions. The maximum conduction current of the bypass diode is 40A, and the minimum reverse withstand voltage is 35V. The four cell arrays are connected in series sequentially, with the negative terminal of the first cell array serving as the negative terminal of the photovoltaic module, and the positive terminal of the last cell array serving as the positive terminal of the photovoltaic module. Each cell string is composed of multiple cell strings divided into segments connected in series. The number and size of the cell strings in each cell array are the same, and the cell strings are divided into two, three, or four segments; preferably, they are three or four segments.
[0026] The spacing between adjacent battery string slices in the battery string is -2 to 2 mm. When the spacing between battery string slices is negative, the edges of two adjacent battery string slices overlap.
[0027] In the four battery arrays, two battery arrays are arranged in series along the longitudinal direction. The length of the battery strings can be the same or different. Preferably, when the number of battery cells in the upper and lower battery arrays is asymmetrically arranged, the length of the battery string protected by the bypass diode does not exceed 26-32 battery cells.
[0028] The battery strings in the battery array are connected by busbars. The busbars are tin-plated copper busbars with a thickness of 0.1~0.3 mm and a width of 3~10 mm. The busbars are located between adjacent battery arrays arranged longitudinally or on the back of the battery array, which can increase the effective power generation area of the photovoltaic module and increase the module power.
[0029] Example 2
[0030] like Figure 1As shown, a photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions. Each cell array consists of three cell strings of the same length connected in parallel. A bypass diode is provided next to each of the four cell arrays to protect the cell arrays from shading or hot spots. The bypass diode has a maximum conduction current of 40A and a minimum reverse withstand voltage of 35V. The four cell arrays are connected in series. Each cell string is composed of multiple cell strings divided into segments connected in series. The three cell strings in each cell array have the same number and size of cell segments. The cell array uses 210mm*210mm cells. The cell strings are divided into three segments, with each cell string in each array consisting of 18 cells and a spacing of -0.5 to -1.5 mm.
[0031] The two upper battery arrays arranged horizontally have three battery strings connected in parallel via two first busbars 1, and the two lower battery arrays have three battery strings connected in parallel via second busbars 2. The two lower battery arrays are connected in series via second busbars 2, while the two upper battery arrays are not connected to each other. Two adjacent battery arrays arranged vertically are connected in series via two third busbars 3. Two fourth busbars 4 are located between the first busbars 1 and the third busbars 3, respectively connected to their corresponding first busbars 1 and third busbars 3. The two fourth busbars 4 extend through openings in the photovoltaic backsheet or back glass, and their leads are connected to the positive and negative terminals of bypass diodes via junction boxes. Alternatively, the bypass diodes can be directly installed inside the photovoltaic module; in this case, ultra-thin bypass diodes can be used, with their positive and negative terminals connected to the two fourth busbars 4 respectively.
[0032] The glass dimensions are 2465*1303*2.0 mm, with the same dimensions on both the front and back. Four holes, 10-15 mm in diameter, are drilled symmetrically on the back glass; these holes can be round or oval. The center of each hole can be located on the back of the solar cell or between two solar cell strings. These holes are for the two fourth busbar leads to pass through and be soldered to the bypass diode in the junction box.
[0033] Two battery strings arranged longitudinally are connected in series through a third busbar 3. There are two ways to do this: the first is to place it between the battery arrays, with a busbar width of 4 mm and a thickness of 0.3 mm; the second is to place it on the back of the battery cells. In this case, in order to reduce cell breakage during the production process and improve product yield, the busbar is preferably selected with a thickness of less than 0.15 mm and a width of 5~10 mm.
[0034] Preferably, four 15 mm diameter holes are made on the back plate or back glass, located at the center of the four battery arrays respectively (the hole positions can be flexibly adjusted according to the actual process to facilitate actual production operation). One end of each of the two fourth busbars 4 is welded to the first busbar 1 and the third busbar 3 respectively, and the other end is led out through the holes on the back plate or back glass. The leads of the fourth busbars 4 of the other battery arrays are also led out from the holes in the same way. Finally, a junction box is installed at the hole, so that the leads of the fourth busbars 4 pass through the through hole at the bottom of the junction box and are welded to the positive and negative terminals of the bypass protection diode inside the junction box for conduction.
[0035] This photovoltaic module can achieve a power output of 750~800 W or more, and it contains a total of 68~72 solar cells. It is equipped with four bypass protection diodes, each of which protects 18 solar cells, and has excellent anti-hot spot effect.
[0036] Example 3
[0037] like Figure 1 As shown, a photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions. Each cell array consists of three cell strings of the same length connected in parallel. A bypass diode is provided next to each of the four cell arrays to protect the cell arrays from shading or hot spots. The bypass diode has a maximum conduction current of 40A and a minimum reverse withstand voltage of 35V. The four cell arrays are connected in series. Each cell string is composed of multiple cell string slices connected in series. The number and size of the cell string slices in the three cell strings within each cell array are the same. Each cell string in each array contains 28 cell strings. The cell array uses 210mm*182mm cells. The cell string slices are quarter-sliced, with each cell string in each array containing 18 cells and a slice spacing of -0.5 to -1.5 mm.
[0038] The two upper battery arrays arranged horizontally have three battery strings connected in parallel via two first busbars 1, and the two lower battery arrays have three battery strings connected in parallel via second busbars 2. The two lower battery arrays are connected in series via second busbars 2, while the two upper battery arrays are not connected to each other. Two adjacent battery arrays arranged vertically are connected in series via third busbars 3. Two fourth busbars 4 are located between the first busbars 1 and the third busbars 3, respectively connected to their corresponding first busbars 1 and third busbars 3. The two fourth busbars 4 extend through openings in the photovoltaic backsheet or back glass, and their leads are connected to the positive and negative terminals of bypass diodes via junction boxes. Alternatively, the bypass diodes can be directly installed inside the photovoltaic module; in this case, ultra-thin bypass diodes can be used, with their positive and negative terminals connected to the two fourth busbars 4 respectively.
[0039] The glass dimensions are 2459*1128*2.0 mm, with the same dimensions on both the front and back. Four holes, 10-15 mm in diameter, are drilled symmetrically on the back glass; these holes can be round or oval. The center of each hole can be located on the back of the solar cell or between two solar cell strings. These holes are for the two fourth busbar leads to pass through and be soldered to the bypass diode in the junction box.
[0040] Two battery strings arranged longitudinally are connected in series through a third busbar 3. There are two ways to do this: the first is to place it between the battery arrays, with the busbar being 4 mm wide and 3 mm thick; the second is to place it on the back of the battery cells. In this case, in order to reduce cell breakage during the production process and improve product yield, the busbar is preferably selected with a thickness of less than 0.15 mm and a width of 5 to 10 mm.
[0041] Preferably, four 15 mm diameter holes are made on the back plate or back glass, located at the center of the four battery arrays respectively (the hole positions can be flexibly adjusted according to the actual process to facilitate actual production operation). One end of each of the two fourth busbars 4 is welded to the first busbar 1 and the third busbar 3 respectively, and the other end is led out through the holes on the back plate or back glass. The leads of the fourth busbars 4 of the other battery arrays are also led out from the holes in the same way. Finally, a junction box is installed at the hole, so that the leads of the fourth busbars 4 pass through the through hole at the bottom of the junction box and are welded to the positive and negative terminals of the bypass protection diode inside the junction box for conduction.
[0042] This photovoltaic module can achieve a power output of 650~700 W or more, and it contains a total of 68~72 solar cells. It is equipped with four bypass protection diodes, each of which protects 28 solar cells, and has excellent anti-hot spot effect.
[0043] Example 4
[0044] like Figure 2 As shown, a photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions. Each cell array consists of three cell strings of the same length connected in parallel. The cell arrays use 210mm*182mm cells. A bypass diode is provided next to each of the four cell arrays to protect the cell arrays from shading or hot spots. The bypass diode has a maximum on-state current of 40A and a minimum reverse withstand voltage of 35V. The four cell arrays are connected in series. Each cell string is composed of multiple cell string segments connected in series, and the number and size of the cell string segments in the three cell strings within each cell array are the same.
[0045] The total number of battery string slices in the adjacent battery arrays arranged vertically on the left is less than 24, and the adjacent battery arrays arranged vertically on the left share a bypass diode; similarly, the total number of battery string slices in the adjacent battery arrays arranged vertically on the right is less than 24, and the adjacent battery arrays arranged vertically on the right share a bypass diode.
[0046] The battery string is divided into three sections, with a total length of 26 sections for adjacent battery arrays arranged longitudinally, and a section spacing of -0.5mm to -1.5mm.
[0047] The glass dimensions are 1756*1128*2.0 mm, with the same dimensions on both the front and back. Two holes, 10-15 mm in diameter, are made on the back glass, symmetrically arranged and can be either round or oval. The center of the holes can be located on the back of the solar cells or between two solar cell strings, 100-300 mm from the short side of the glass. These holes are for the two fourth busbar leads to pass through and be soldered to the bypass diodes in the junction box.
[0048] In this embodiment, the photovoltaic module has a short cell string length, equivalent to two cell arrays on the left and right, thus eliminating the need for a third busbar 3 for connecting the upper and lower cell arrays in series. The lower positive and negative terminals of the two cell arrays are connected in series via a second busbar 2, while the upper terminals are not conductive.
[0049] This photovoltaic module can achieve a power output of 450-500W or more. It contains a total of 50 complete solar cells and is equipped with two bypass protection diodes, each protecting 26 solar cells, providing excellent anti-hot spot performance.
[0050] Example 5
[0051] like Figure 3 As shown, a photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions. Each cell array consists of three cell strings of the same length connected in parallel. A bypass diode is provided next to each of the four cell arrays to protect the cell arrays from shading or hot spot conditions. The bypass diode has a maximum on-state current of 40A and a minimum reverse withstand voltage of 35V. The four cell arrays are connected in series sequentially. Each cell string is composed of multiple cell string slices connected in series, and the number and size of the cell string slices in the three cell strings within each cell array are the same.
[0052] The two battery arrays arranged horizontally at the top each have fewer than 24 battery string slices, and each of the two battery arrays arranged horizontally at the top has a bypass diode. The total number of battery string slices of the adjacent battery arrays arranged horizontally at the bottom is less than 24, and the adjacent battery arrays arranged horizontally at the bottom share a bypass diode.
[0053] Example 6
[0054] As an extreme case of Embodiments 4 and 5, a photovoltaic module includes: four cell arrays arranged adjacent to each other in both the horizontal and vertical directions. Each cell array consists of three cell strings of the same length connected in parallel, and the four cell arrays are connected in series sequentially. Each cell string is composed of multiple cell string slices connected in series. The number and size of the cell string slices in the three cell strings of each cell array are the same. The total number of cell string slices in the four cell arrays is less than 24. The four cell bypass arrays share a single bypass diode. The upper and lower cell arrays are directly connected by solder strips for welding series-connected cell cells.
[0055] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.
Claims
1. A photovoltaic module, characterized by, include: Four battery arrays are arranged adjacent to each other in both the horizontal and vertical directions. Each battery array consists of three battery strings of the same length connected in parallel. Each battery string is composed of multiple battery strings connected in series in segments. A bypass diode is provided next to each of the four battery arrays. The four battery arrays are connected in series in sequence.
2. A photovoltaic module according to claim 1, wherein, The battery string is divided into two, three, or four segments.
3. A photovoltaic module according to claim 2, wherein, The number of battery cells divided into segments is 24 to 30.
4. A photovoltaic module according to claim 2, wherein, The number of battery string segments is less than 24.
5. A photovoltaic module according to claim 2, wherein, The spacing between adjacent battery string segments in the battery string is -2 to 2 mm.
6. A photovoltaic module according to claim 1, wherein, The battery strings in the battery array are connected by a busbar, which is a tin-plated copper busbar.
7. A photovoltaic module according to claim 6, characterized in that, The busbar is located between adjacent battery arrays arranged longitudinally, or on the back of the battery array.
8. A photovoltaic module according to claim 3, wherein, Each of the battery arrays is provided with a bypass diode.
9. A photovoltaic module according to claim 4, wherein, The total number of battery string slices in adjacent battery arrays arranged longitudinally is less than 24, and adjacent battery arrays arranged longitudinally share a single bypass diode.
10. A photovoltaic module according to claim 4, wherein, The total number of battery string slices in adjacent battery arrays arranged horizontally is less than 24, and adjacent battery arrays arranged horizontally share a single bypass diode.