SOLAR MODULE

Description

[0001] The invention relates to a solar module. In particular, the invention relates to a solar module with at least two substring groups. Such a solar module is known from unpublished prior art, which is described in Fig. 1 shown.

[0002] Fig. 1 Figure 1 shows the solar module, which has a substring group A, a substring group B, and a substring group C. Each substring group A, B, C has an upper substring A1, B1, C1 with a number N of series-connected solar cells 11. The number N of series-connected solar cells 11 can be arbitrary, but N ≥ 2 must be interconnected. The solar cells 11 of the upper substrings A1, B1, C1 are arranged in a matrix of two adjacent columns with, for example, twelve rows, where the solar cells 11 are configured as twenty-four so-called half-cells, since they are cut in half after manufacturing. Each substring group A, B, C also has a lower substring A2, B2, C2 with a number 21 of series-connected solar cells.The solar cells 21 are also arranged in a matrix of two adjacent columns and twelve rows, with the solar cells 21 also configured as twenty-four half-cells. The lower substring A2,B2,C2 and the upper substring A1,B1,C1 contain the same number of solar cells 11,21, which are both connected in parallel. Internally, within each substring A1,B1,C1,A2,B2,C2, twenty-four solar cells 11,21 are connected in series as half-cells. Thus, a total of six times twenty-four half-cells are interconnected in the solar module.

[0003] The solar module also has a cross-connector 3, which electrically connects the lower substring A2,B2,C2 and the upper substring A1,B1,C1 in parallel to the substring group A,B,C. The cross-connectors 3 of each substring group A,B,C are connected to each other in such a way that the substring groups A,B,C are electrically connected in series. The cross-connectors 3 are located in the center of the solar module.

[0004] The solar module also features three bypass diodes 4, which are electrically arranged in the cross-connector 3. Each bypass diode 4 is assigned to one of the substring groups A, B, C and protects two sets of twenty-four solar cells 11, 21 within the module.

[0005] The cross connectors 3 and the bypass diodes 4 are each positioned centrally. Because the solar module is divided into two equal halves by the cross connectors 3 and the bypass diodes 4, partial shading of the lower substrings has a less pronounced effect when the solar module is mounted vertically than in a solar module where the bypass diodes are not centrally located. Due to the centrally positioned bypass diodes 4, the solar module can still produce up to 50% of its power even if it is partially shaded. The terms "upper" and "lower" substring refer to the arrangement of the two substrings within the substring group relative to each other.

[0006] Solar modules are typically supplied in various length and width dimensions to meet different size requirements, for example, on building roofs or facades. In the case of the Fig. 1 However, in the solar module configuration shown, it is necessary to increase the number of solar cells per substring group by at least two rows – that is, one row per substring – in order to change the solar module size in the vertical direction. This is because the solar module only functions if the lower substring and the upper substring of the substring group, which is electrically connected in parallel to it, have the same number of identical solar cells.

[0007] Preferably, a solar module is manufactured using square or substantially square solar cells. Such solar cells are designed as full cells, while half cells represent two halves of a full cell that were cut in half during manufacturing. Furthermore, it is also possible to divide manufactured cells into thirds, quarters, or fifths and assemble these partial cells into solar modules. Full cells, for example, have an edge length of approximately 156 mm x 156 mm, which are also referred to as 6-inch (6") cells. However, full cells can also have other sizes.

[0008] In the Fig. 1 In the example solar module shown, the solar cells 11, 21 are provided as half-cells, as they are cut in half. These solar cells 11, 12 are arranged in such a way that a specific solar module size results from their arrangement alone. Predetermined distances between the half-cells of, for example, 4 to 5 mm and, if necessary, edge distances to a frame of the solar module on the order of a few centimeters result in a typical solar module size, which represents a standard size.

[0009] Depending on the number of solar cells installed in the solar module, the module sizes vary, but they have standard dimensions. These standard dimensions arise primarily because solar modules typically use three substring groups, each with two columns.

[0010] GB 2564123 A describes a solar module with three substring groups, containing solar cells divided into six groups of twenty solar cells each, connected to form strings. A junction box contains three bypass diodes and is connected to the strings via cables. The number of solar cells in the upper substring and the number of solar cells in the lower substring are each even.

[0011] EP 3 959 748 A1 describes a solar module with multiple substring groups, each substring group having an upper substring and a lower substring, each with two columns and multiple rows. The columns of the upper and lower substrings can contain an odd number of solar cells. The entire structure is built from half-cells.

[0012] For example, the in Fig. 1 The solar module shown, with its three substring groups A, B, C and twenty-four solar cells 11, 21 per substring group A1, B1, C1, A2, B2, C2, comprises solar cells 11, 12 in the form of half-cells with a width of 156.75 mm, a height of 78.38 mm, and an area of ​​122.16 cm², is a 3,000 mm long substring group. The columns of the substring groups A, B, C then extend over approximately 2,000 mm for 24 solar cells per substring. In a solar module corresponding to the one shown in Fig. 1 The solar module shown is identical except that it has twenty-six solar cells per substring group; however, the columns of substring groups A, B, and C extend over approximately 2,200 mm. In a solar module corresponding to the one shown in Fig. 1 The solar module shown corresponds, with the difference that it has twenty-two solar cells per substring group, in which the columns of substring groups A, B, C extend over approximately 1,800 mm.

[0013] A solar module with a similar structure to the one in Fig. 1 The solar module shown therefore has standard dimensions which vary depending on the number of solar cells per substring and the number of substring groups, but due to the standard size of the solar cells, its size change is relatively fixed and exhibits a relatively large size change in the vertical direction when the number of solar cells is changed.

[0014] However, it is desirable to provide a solar module that allows for a more finely granular vertical size change and, in particular, has intermediate sizes.

[0015] Especially when the solar module is intended for integration into rooftop or architectural applications, such as facade elements, it is desirable to be able to vary the module size in relatively fine increments. This is also desirable to improve laminator utilization in the production process, as laminators often have fixed length and width dimensions designed to allow multiple solar module laminates of defined dimensions to be laminated together in a single machine, thus increasing throughput. The aim is to fill the laminator's surface area with as many adjacent solar module laminates as possible. If the dimensions of the solar module laminates change in comparatively large increments, the point is reached more quickly where fewer adjacent solar module laminates can be processed in the laminator.

[0016] It is therefore an object of the invention to provide a solar module that allows for a more finely granulated vertical size change. This object is achieved by a solar module with the features of claim 1.

[0017] According to the invention, it is provided that two columns of the lower substring have a different number of solar cells and that two columns of the upper substring belonging to the substring group have a different number of solar cells, so that the number of solar cells of the upper substring and the number of solar cells of the lower substring is odd.

[0018] This design allows the substring group to be increased vertically by one row of solar cells, thus halving the size change of the solar module compared to conventional designs. This enables a smaller change in the vertical solar module size than in the prior art. As a result, new solar module sizes are available, representing intermediate sizes between known standard sizes. This also offers the advantage of more space-efficient use of the laminators for laminating the solar module laminates.

[0019] In a preferred embodiment, the upper substring and the lower substring belonging to the substring group are configured and designed such that they generate the same electrical voltage under the same illumination. The phrase "the same electrical voltage" is understood to mean the same electrical voltage within measurement error tolerances. If the upper and lower substrings of a substring group are not designed to generate the same electrical voltage under the same illumination, compensating currents will flow, rendering the solar module inoperable or at least uneconomical.

[0020] Preferably, the upper and lower substrings each comprise solar cells of the same dimensions, arranged in two adjacent columns. This allows the substrings to efficiently fill the solar module area.

[0021] The solar cells are designed as solid cells. The size of an individual solid cell depends, among other things, on the manufacturing process of the solar cell. For example, the size of a silicon wafer solid cell is 156 mm x 156 mm, i.e., the solid cell is a so-called 6-inch (6") cell. Preferably, the solid cells are square or substantially square in shape.

[0022] In a non-inventive embodiment, the solar cells are designed as half-cells. Half-cells are solar cells that, after being manufactured as full cells, are cut in half. This cell division increases the total area of ​​the intercellular spaces on the solar module surface compared to the total intercellular space of corresponding solar cells that are not divided. This results in a higher reflection gain across the backsheet. Furthermore, electrical conduction losses are reduced by halving the current per substring and requiring a higher number of cell connectors. Designing the solar cells as half-cells also allows for more precise size variations of the solar module than when the solar cells are designed as full cells, by adding or removing solar cells from the substrings.Beyond the non-inventive design as half-cells, it is also possible to divide manufactured cells into thirds, quarters or fifths and to assemble these partial cells into solar modules.

[0023] Preferably, at least two substring groups are electrically connected in series. More preferably, three substring groups are electrically connected in series. Preferably, the solar cells of the solar module are arranged in six columns, i.e., each of the three substring groups has two columns.

[0024] The serially connected substring groups can be configured such that they each generate different electrical voltages when illuminated. In a preferred embodiment, the substring groups are configured such that they each generate the same voltage under the same illumination.

[0025] Preferably, each substring group is assigned a bypass diode in the area of ​​the electrical parallel connection between the associated upper substring and the associated lower substring. This allows significantly more power to be generated even in the case of partial shading of the solar module surface compared to the absence of bypass diodes.

[0026] Preferably, all substring groups have the same number of solar cells. This provides a solar module that can be easily configured into a rectangular shape. Thus, the solar cells, which are usually square or rectangular, are arranged in a space-saving manner within a rectangular solar module.

[0027] In a preferred embodiment, one of the substring groups has a different number of solar cells than the other substring group or groups. This allows the solar module to be adapted to a desired geometry.

[0028] Preferably, the solar cells are designed as silicon wafer solar cells. Non-inventive half-cells can be easily cut from these.

[0029] An embodiment of the invention is shown schematically in the drawings and is described in more detail below. The drawings are shown schematically and not to scale. Fig. 1 a top view of a solar module according to the state of the art; and Fig. 2 A top view of a solar module according to the invention.

[0030] Fig. 1 This shows a top view of a solar module according to the state of the art and has already been explained in the introductory description. Therefore, to avoid repetition, reference is made to the preceding description.

[0031] Fig. 2 shows a top view of a solar module according to the invention. The in Fig. 2 The solar module shown corresponds to the one in Fig. 1The solar module shown differs in that all solar cells 11,21 are designed as full cells and two columns of the lower substring A2,B2,C2 have a different number of solar cells 21 and that two columns of the upper substring A1,B1,C1 belonging to the substring group A,B,C have a different number of solar cells 11, so that the number of solar cells 11 of the upper substring A1,B1,C1 and the number of solar cells 21 of the lower substring A2,B2,C2 is each odd.

[0032] The lower substrings A2, B2, C2 and the upper substrings A1, B1, C1 each contain the same number of solar cells 11, 21. The solar cells 11 of the upper substrings A1, B1, C1 and the solar cells 21 of the lower substrings A2, B2, C2 are each arranged in a matrix consisting of two adjacent columns and several rows, with the solar cells 11 and the solar cells 21 each being configured as twenty-three full cells per substring A1, B1, C1, A2, B2, C2. Internally, twenty-three solar cells 11, 21 are connected in series as full cells in each substring A1, B1, C1, A2, B2, C2. Thus, a total of six × twenty-three solar cells 11, 21 are connected in parallel within the solar module.

[0033] The solar module also features cross-connectors 3, each of which electrically connects the lower substring A2,B2,C2 and the upper substring A1,B1,C1 in parallel to the substring group A,B,C. However, the cross-connectors 3 meander within the electrical circuit of the solar module. Each bypass diode 4 is assigned to one of the substring groups A,B,C and protects two sets of twenty-three solar cells 11,21 within the module. List of reference symbols:

[0034] A1 Upper substring of substring group A A2 Lower substring of substring group A A Substring group A1+A2 B1 Upper substring of substring group B B2 Lower substring of substring group B B Substring group B1+B2 C1 Upper substring of substring group C C2 Lower substring of substring group C C Substring group C1+C2 11 Solar cells of the upper substrings 21 Solar cells of the lower substrings 3 Cross connectors 4 Bypass diodes

Claims

1. A solar module having at least two substring groups (A,B,C), each substring group (A,B,C) comprising - an upper substring (A1,B1,C1) having a number of solar cells (11) that are connected in series, wherein the solar cells (11) of the upper substring (A1,B1,C1) are arranged in a matrix form comprising at least two adjacent columns and multiple rows, - a lower substring (A2,B2,C2) having a number of solar cells (21), that are connected in series, wherein the solar cells (21) are arranged in a matrix form comprising at least two adjacent columns and multiple rows and wherein the lower substring (A2,B2,C2) and the upper substring (A1,B1,C1) have the same number of solar cells (11,21) and - a transverse connector (3) electrically connects the lower substring (A2,B2,C2) and the upper substring (A1,B1,C1) in parallel to form the substring group (A,B,C) and - a bypass diode (4) that is electrically arranged in the transverse connector (3), wherein the transverse connector (3) of each substring group (A,B,C) are in contact with one another in such a manner that the substring groups (A,B,C) are electrically connected to one another in series, wherein the solar cells (11, 21) are designed as full cells, characterized in that two columns of the lower substring (A2,B2,C2) have a different number of solar cells (21) and that two columns of the associated upper substring (A1,B1,C1) in the substring group (A,B,C) have a different number of solar cells (11) with the result that the number of solar cells (11) of the upper substring (A1,B1,C1) and the number of solar cells (21) in the lower substring (A2,B2,C2) is uneven.

2. The solar module as claimed in claim 1, characterized in that the upper substring (A1,B1,C1) and the associated lower substring (A2,B2,C2) in the substring group (A,B,C) are oriented and designed in such a manner that when exposed to the same amount of light they generate the same electrical voltage.

3. The solar module as claimed in claim 1 or 2, characterized in that the upper substrings (A1,B1,C1) and the lower substrings (A2,B2,C2) each have solar cells (11,21) that have identical dimensions and are arranged in two adjacent columns.

4. The solar module as claimed in one of claims 1 to 3, characterized in that the solar cells (11,21) are designed as half cells.

5. The solar module as claimed in one of the preceding claims, characterized in that at least two substring groups (A,B,C) are electrically connected to one another in series.

6. The solar module as claimed in one of the preceding claims, characterized in that the two substring groups (A,B,C) are designed in such a manner that they each generate the same voltage or different electrical voltages.

7. The solar module as claimed in one of the preceding claims, characterized in that a bypass diode (4) is allocated respectively to each substring group (A,B,C) in the region of the electrical parallel interconnection between the associated upper substring (A1,B1,C1) and the associated lower substring (A2,B2,C2).

8. The solar module as claimed in one of the preceding claims, characterized in that all substring groups (A,B,C) have the same number of solar cells (11,21).

9. The solar module as claimed in one of claims 1 to 7, characterized in that one of the substring groups (A,B,C) has a different number of solar cells than the other substring group (A,B,C) or the other substring groups (A,B,C).

10. The solar module as claimed in one of the preceding claims, characterized in that the solar cells (11,21) are designed as silicon wafer solar cells.