Methods for manufacturing a shingled crisscross matrix of solar cells
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- SOLARWAT
- Filing Date
- 2024-08-12
- Publication Date
- 2026-06-24
AI Technical Summary
Existing solar panel manufacturing processes are complex and time-consuming, requiring the use of busbars that increase production costs and reduce efficiency by blocking incoming light.
A method for manufacturing shingled crisscross matrix solar cells using a single conductive foil instead of busbars, which simplifies the production process, reduces manufacturing time, and enhances efficiency by minimizing light obstruction.
The solution significantly reduces production costs and time while improving solar panel efficiency by eliminating the need for busbars and simplifying the manufacturing process.
Smart Images
Figure IL2024050809_20022025_PF_FP_ABST
Abstract
Description
[0001] METHODS FOR MANUFACTURING A SHINGLED CRISSCROSS
[0002] MATRIX OF SOLAR CELLS
[0003] FIELD OF THE INVENTION
[0004] The present invention relates to systems and methods for manufacturing solar array modules for generating electric-power and more particularly, to systems and methods having PV solar cells interconnected in a crisscross matrix array configuration.
[0005] BACKGROUND OF THE INVENTION
[0006] A conventional solar panel manufacturing line utilizing several conventional electric busbars connection technology by using several conductors with round or rectangular cross section, wherein the soldering and lamination processes are separated. A mostly automatic production line that utilizes common process for producing PV panels with regular solar cells, one can refer to a video in the following link:
[0007] The mainstream technological process for solar panel manufacturing involves placement the several quantities of Busbars or Smart Wires (SW) on cell and afterword soldering the Busbars or SW into a metallization layer of PV solar cells including cell to cell serial interconnection and / or matrix interconnection. In most PV modules, the cells are placed with gaps between all neighboring cells, which require increasing the panel length and / or width.
[0008] The present disclosure also relates to manufacturing lines and processes of shingled photo-voltaic (PV) solar panels. Shingled photo-voltaic (PV) solar panels are known in the art.
[0009] PCT / IL2021 / 050943 discloses systems and methods for manufacturing solar array modules configured to generate electric-power and more particularly, to systems having PV solar sub cells interconnected in a crisscross matrix array configuration, wherein all solar cells are interconnected both in serial and in parallel, and the solar cells may be cut into sub cells; and solar cells are placed proximal to each other with a gap ranging from zero to a few millimeters; and wherein the production line includes placing busbars or groups of Smart Wire (SW) conductors on each of the n columns of the solar sub-cells to thereby electrically connect the columns of the solar sub-cells in series. PCT / IL2021 / 050943 further discloses placing and soldering short parallel jumpers between all pairs of neighboring the solar sub-cells in each of the m rows of the solar subcells, and thereby electrically connect the columns of the solar sub-cells in parallel.
[0010] US 63 / 532,427 further discloses methods for manufacturing a shingled crisscross matrix of solar cells, using multiple layers of foils.
[0011] US 63 / 541,305 further discloses methods for manufacturing a shingled crisscross matrix of solar cells, using multiple layers of foils, glues.
[0012] There is therefore a need, and it would be advantages to provide production lines for manufacturing shingled solar panels having a crisscross matrix array of solar, wherein such production lines will provide reduced complexity of the process, and the time now required to execute all of the manufacturing steps, and consequently, substantially decrease the process efficiency and reduce the manufacturing time and the automatic line equipment cost. It would be further advantages to eliminate the use of busbars in the production lines of solar panels in terms of costs and production time, using a single conductive foil.
[0013] SUMMARY OF THE INVENTION
[0014] Unless otherwise defined herein, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein may be used in the practice or testing of embodiments of the invention, example methods and / or materials are described below. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.
[0015] It should be noted that the terms “electrical” or “electrically wired”, as used herein refer to the electrical configuration of the matrix, regardless of the physical configuration of the solar cells in the solar panel. Similarly, it should be further noted that the term “physical” as used herein refers to the physical placement of solar cells in the module / panel, regardless of the electrical inter-wiring of the solar cells. It should be appreciated that the present disclosure eliminates the use of busbars which substantially reduces the manufacturing cost and time of the solar panel, as well as increase the solar panel efficiency, since the busbars block the incoming light.
[0016] BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will become fully understood from the detailed description given herein below and the accompanying drawings, which are given by way of illustration and example only and thus not limitative of the present disclosure, and wherein:
[0018] Fig. 1 is an example schematic illustration of a side cross section view of a prior art PV solar cell (or sub-cell).
[0019] Fig. 2 schematically illustrates an example prior art solar-array module, in a shingled formation, arranged in a crisscross configuration of solar cells.
[0020] Fig. 3a is a cross-section view of an example wide strip of a pliable conductive strip for interconnecting two shingled rows of PV solar cells in a crisscross matrix, according to embodiments of the present invention.
[0021] Fig. 3b is a side view of an example embodiment concept of a manufacturing process of interconnecting two shingled rows of PV solar cells, in a crisscross matrix, using the wide strip of a pliable conductive strip shown in Fig. 3a, according to embodiments of the present invention.
[0022] Fig. 4a is a cross-section view of an example wide strip of a pliable conductive strip for interconnecting two shingled rows of PV solar cells in a crisscross matrix, according to embodiments of the present invention.
[0023] Fig. 4b is a side view of an example embodiment concept of a manufacturing process of interconnecting two shingled rows of PV solar cells, in a crisscross matrix, using the wide strip of a pliable conductive strip shown in Fig. 4a, according to embodiments of the present invention.
[0024] Fig. 4c is a cross-section view of an example wide strip of a pliable conductive strip for interconnecting two shingled rows of PV solar cells in a crisscross matrix, according to embodiments of the present invention.
[0025] Fig. 4d is a side view of an example embodiment concept of a manufacturing process of interconnecting two shingled rows of PV solar cells, in a crisscross matrix, using the wide strip of a pliable conductive strip shown in Fig. 4c, according to embodiments of the present invention.
[0026] Fig. 5 is a cross-section view of an example conductive glue line matter for interconnecting two shingled rows of PV solar cells in a crisscross matrix, according to embodiments of the present invention.
[0027] DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown.
[0029] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided, so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0030] An embodiment is an example or implementation of the disclosure. The various appearances of "one embodiment," "an embodiment" or "some embodiments" do not necessarily all refer to the same embodiment. Although various features of the disclosure may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the disclosure may be described herein in the context of separate embodiments for clarity, the disclosure may also be implemented in a single embodiment.
[0031] Reference in the specification to "one embodiment", "an embodiment", "some embodiments" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one embodiment, but not necessarily all embodiments, of the disclosures. It is understood that the phraseology and terminology employed herein are not to be construed as limiting and are for descriptive purposes only.
[0032] Meanings of technical and scientific terms used herein are to be commonly understood as to which the disclosure belongs, unless otherwise defined. The present disclosure can be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.
[0033] The shingling formation maufacturing
[0034] The present invention relates to PV solar cells panels of in which panels solar cells are arranged in shingled formation. The solar cells may be standard solar cells, or solar sub-cells yield when cutting standard solar cells into “k” sub-cells (or manufactured in smaller form, from preconfigured smaller size wafer). The present invention is described in terms of solar cells, which refers to both standard solar cells and or solar sub-cells.
[0035] Reference is made to the drawings. Fig. 1 illustrates an example side cross section view of a prior art PV solar cell (or sub-cell) 100 according to embodiments of the present invention, wherein PV solar cell 100 is typically, with no limitations, made of silicon (or any other material with opposite polarities) having contacts placed on opposite sides of the wafer (positive on one side of the photovoltaic wafer 110, and negative on the other, for example, sides 130 / 132 in Fig. 1). PV solar cell (or sub-cell) 100 includes a common body (wafer) 110 having a front side 120 and a rear side 122, wherein typically, with no limitations, the upper side is the plus, positive (+) side, that is shown facing the incoming light 10, and the lower side is the negative (-) side. However, depending on the solar cell wafer technology, either the upper side of PV solar cell 100 or the lower side or both of these sides may be exposed to incoming light 10. Typically, with no limitations, the upper side of each PV solar cell 100 is covered by an upper conductive contact grid 130 that includes a network of thin conductors that are configured to collect the electric current generated by the PV solar cell 100. Typically, the lower sides of each PV solar cell 100 is covered by a lower conductive contact grid 132.
[0036] Reference is also made to Fig. 2, schematically showing an example prior art solararray module 105, in a shingled formation, arranged in a crisscross configuration of solar cells 100. In this, example, solar-array module includes nXm adjacent solar cells 100 (as shown, with no limitations), arranged, by way of a non-limiting example, in 8 columns (m strings: ci-cs) and n rows (ri-rn), wherein each column (string) includes n solar cells 100, that are also interconnected in parallel, forming a crisscross configuration of solar cells (in this non-limiting example, solar cells 100.
[0037] PV solar cells 100 (referred to, herein also as solar cell 100) further include a bottom-front (-) contact pad 140 and an upper-rear (+) contact pad 142. When production is completed, the front-end side of a rear is placed over the rear end side of the adjacent front cell 100, such that the bottom-front (-) contact pad 140r of the rear solar cell lOOr is conductively connected to the upper-rear (+) contact pad 142f of the front solar cell lOOf
[0038] Reference is now made to Figs. 3a, and 3b: Fig. 3a is a cross-section view of an example wide strip of a pliable conductive strip for interconnecting two shingled rows of PV solar cells in a crisscross matrix 200, according to embodiments of the present invention; and Fig. 3b is a side view of an example embodiment concept of a manufacturing process of interconnecting two shingled rows of PV solar cells 100, in a crisscross matrix, using wide strip of a pliable conductive strip 250, according to embodiments of the present invention. Fig. 3b illustrates a side view of an embodiment concept of a manufacturing process of connecting shingled PV solar cells, in a crisscross matrix (such as crisscross matrix 105), to form a PV solar panel 200.
[0039] In order to construct the cells’ (100) shingled formation, the following steps take place:
[0040] • Providing a wide strip of pliable conductive tape 250 having, for example, a thin layer of conductive metal 252, such as, with no limitations, copper, and having a lower surface 252dn and an upper surface 252up. The pliable conductive tape may further include an upper glue layer 251up and a lower glue layer 251dn. Glue layers 251 may be conductive or non-conductive. The pliable conductive tape and upper glue 251up layer are sized to accommodate bottom-front (-) contact pad 140r of the rear solar cell lOOr; and pliable conductive tape and lower glue layer 251dn are sized to accommodate upper-rear (+) contact pad 142f of the front solar cell lOOf, as shown in Fig. 3b.
[0041] • A first row of solar cells lOOf is placed over the designated production line surface, wherein the solar cells lOOf are placed adjacent to each other (see, for example, Fig. 2).
[0042] • The glue may also serve as soldering matter.
[0043] • After the soldering (or plainly just heating in a lower temperature) production step takes place, the conductive tape 250 conductively interconnects the bottom-front ends (-) contact pads 140r of the rear solar cells lOOr, with the respective upper-rear ends (+) contact pad 142f (for example) of the respective front solar cells lOOf (for example). Thereby, a crisscross matrix of solar cells is formed.
[0044] Reference is now made to Figs. 4a, and 4b: Fig. 4a is a cross-section view of an example wide strip of a pliable conductive strip for interconnecting two shingled rows of PV solar cells in a crisscross matrix, according to embodiments of the present invention; and Fig. 4b is a side view of an example embodiment concept of a manufacturing process of interconnecting two shingled rows of PV solar cells 100, in a crisscross matrix, using the wide strip of a pliable conductive strip 350, according to embodiments of the present invention. Fig. 4b illustrates a side view of an embodiment concept of a manufacturing process of connecting shingled PV solar cells, in a crisscross matrix (such as crisscross matrix 105), to form a PV solar panel 300.
[0045] In order to construct this cell’ s (100) shingled formation of PV solar panel 300, the following steps take place:
[0046] • Providing a wide strip of pliable conductive tape 350A having, for example, a thin layer of conductive metal 352, such as, with no limitations, copper, and having a lower surface 352dn and an upper surface 352up. The pliable conductive tape further includes an upper conductive glue layer 351up and a lower conductive glue layer 351dn.
[0047] • Conductive metal 352, upper conductive glue layer 351up and a lower conductive glue layer 351dn are of similar dimensions, and sized to accommodate bottom-front (-) contact pad 140r of the rear solar cell lOOr; and pliable conductive tape and lower conductive glue layer 351dn are sized to accommodate upper-rear (+) contact pad 142f of the front solar cell lOOf, as shown in Fig. 4b.
[0048] • A first row of solar cells lOOf is placed over the designated production line surface, wherein the solar cells lOOf are placed adjacent to each other (see, for example, Fig. 2).
[0049] • A wide strip of the pliable conductive tape / foil / coil 350A is placed over the rear end of the solar cells of the first raw of solar cells lOOf, preferably, with no limitations, the whole row of solar cells lOOf, wherein lower conductive glue layer 351dn is placed over to the upper-rear ends (+) contact pad 142f (for example) of the respective front solar cells lOOf.
[0050] • After upper production step takes place, the conductive tape 350A conductively interconnects the bottom-front ends (-) contact pads 140r of the rear solar cells lOOr, with the respective upper-rear ends (+) contact pad 142f (for example) of the respective front solar cells lOOf (for example). Thereby, a crisscross matrix of solar cells is formed.
[0051] Reference is now made to Figs. 4c, and 4d, showing a side view of an embodiment concept of a manufacturing process of connecting shingled PV solar cells, in a crisscross matrix (such as crisscross matrix 300), to form a shingled PV solar panel 301.
[0052] PV solar panel 301 is similar to crisscross matrix 300, but the width of wide strip of pliable conductive tape 350B having but the width of a thin layer of conductive metal 354 is narrower than the width of thin layer of conductive metal 354 of crisscross matrix 300. As such, thin conductive metal 354 is fully surrounded by the layers of conductive glue layer 355dn and glue layer 355up.
[0053] Reference is also now made to Fig. 5, illustrating a side view of an embodiment concept of a manufacturing process of connecting shingled PV solar cells, in a crisscross matrix (such as crisscross matrix 300), to form a shingled PV solar panel 500.
[0054] In order to construct this cell’s (100) shingled formation (500), the following steps take place:
[0055] • Providing a continues source of appliable conductive glue line matter 510.
[0056] • A first row of solar cells lOOf is placed over the designated production line surface, wherein the solar cells lOOf are placed adjacent to each other.
[0057] • Disperse a continuous layer of conductive glue matter 510 on the conductive upper-rear end (+) contact pad 142f of the respective front solar cell lOOf, alongside all strings of adjacent cells without any gaps. The conductive glue will be diffused over the upper-rear ends (+) contact pad 142f of the respective front solar cells lOOf, as illustrated in Fig. 5. Conductive glue matter 510 is applied in a continuous line form. • After the soldering / heating production step takes place, the conductive tape 250 conductively interconnects the bottom-front ends (-) contact pads 140r of the rear solar cells lOOr, with the respective upper-rear ends (+) contact pad 142f (for example) of the respective front solar cells lOOf (for example). Thereby, a crisscross matrix of solar cells is formed.
[0058] While example materials for elements have been described, the present disclosure invention is not limited by these materials.
[0059] Various modifications can be made in the design and operation of the present disclosure invention without departing from its spirit. Thus, while examples of construction of the present disclosure invention have been explained in what is now considered to represent its example embodiments, it should be understood that within the scope of the patent, the present disclosure invention may be practiced otherwise than as specifically illustrated and described.
[0060] The features disclosed in the above description and in the drawings may be significant both individually and in any desired combination in order to realize the various embodiments of the present disclosure.
[0061] Although the present disclosure invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and / or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present disclosure, are contemplated thereby, and are intended to be covered by this patent.
[0062] While certain embodiments of the inventions have been described, wherein these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. The present invention being thus described in terms of several embodiments and examples, it will be appreciated that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are contemplated.
Claims
WHAT IS CLAIMED IS:
1. A method for manufacturing a shingled PV solar cells matrix array (SSCMA) of generally quadrangular solar cells (100), each having a rear side (122), a front side (120), an upper side covered by an upper conductive contact grid (130) coupled with an upperrear conductive pad (142) having a first electric pole (FEP), and a lower side covered by an lower conductive contact grid (132) coupled with a bottom-front conductive pad (140), having a second electric pole (SEP) being opposite to said FEP, wherein each row of the SSCMA includes m solar cells, and each column of the SSCMA includes n solar cells, all of which solar cells are electrically interconnect both in series and in parallel, the method comprising the steps of: a) providing n- wide strips of pliable, parallel-and-serial connection conductors (250, 350A, 350B or 510), each parallel-and-serial connection conductor comprises: i) a thin conductive conductor layer (252) having a lower surface (252dn or 352dn) and an upper surface (252upor 352up); ii) an upper glue layer (25 lupor 35 lup); and iii) a lower glue layer (251dn or 351dn), wherein said upper horizontal surface of each said single layer parallel-and-serial connection conductors (252 or 352), except for the first row, is configured to be conductively attached to the respective upper conductive contact grid of the previous solar cell; and wherein said bottom horizontal surface of each said single conductive layer parallel- and-serial connection conductors, except for the last row, is configured to be conductively attached to the respective lower conductive contact grid of the next solar cell; b) providing mXn PV solar cells; c) assembling the array of mXn PV solar cells wherein comprising the steps of: i) placing a stack row of m of said solar cells onto a flat surface; ii) placing a parallel-and-serial connection conductor over the rear end of the upper conductive contact grids (130) such that the upper glue layers are placed behind the respective lower-front (-) contact pad (140f) and adjacent thereto;iii) placing the next stack row of m of said solar cells onto a flat surface, wherein the front end of each solar cell is placed over the upper glue layer the respective, previously placed solar cell; iv) repeat steps ii-iii until reaching the last stack row of m of said solar cells; and v) placing the nthstack row of m of said solar cells onto a flat surface, wherein the rear end of said lower conductive contact grid (132) of said last placed stack row of m of said solar cells is placed over and adjacent to the previously placed row of m solar cells (100).
2. The method for manufacturing a SSCMA of claim 1, wherein said solar cells (100) are either standard solar cells, solar sub-cells that have been cut into “k” sub-cells from standard solar cells (or manufactured in smaller form from preconfigured smaller size wafer).
3. The method for manufacturing a SSCMA of claim 1, wherein said glue layers are made of conductive gluey matter.
4. The method for manufacturing a SSCMA of claim 3, wherein said thin conductor layer is made of metal.
5. The method for manufacturing a SSCMA of claim 4, wherein said metal is selected from a group including copper and silver.
6. The method for manufacturing a SSCMA of claim 4, wherein said thin conductor layer is solder ready coated on both sides7. The method for manufacturing a SSCMA of claim 3, wherein said conductive gluey matter contains metal.
8. The method for manufacturing a SSCMA of claim 7, wherein said metal is selected from a group including copper and silver.
9. The method for manufacturing a SSCMA of claim 1, wherein said upper glue layer (35 lup) and lower glue layer (35 ldn) remain at their full width; of said thin conductive conductor layer.
10. The method for manufacturing a SSCMA of claim 9, wherein the upper glue layer (355up) and lower glue layer (355dn) maintain the width of upper glue layer (35 lup) and lower glue layer (35 ldn) extend to the full width of said thin conductive conductor layer;said thin conductor layer is narrowed down to allow full contact with the respective conductive pad; said upper glue layer (355up) and lower glue layer (355dn) maintain said width of upper glue layer (35 lup); and glue layers contact each other at their periphery (355).
11. The method for manufacturing a SSCMA of claim 1 further including a step of heating and soldering said assembled array of mXn PV solar cells.
12. The method for manufacturing a SSCMA of claim 1, wherein said PV solar cells are regular solar cells.
13. The method for manufacturing a SSCMA of claim 1, wherein said PV solar cells are cut from regular solar cells (or manufactured in smaller form from preconfigured smaller size wafer).
14. A method for manufacturing a shingled PV solar cells matrix array (SSCMA) of generally quadrangular solar cells (100), each having a rear side (122), a front side (120), an upper side covered by an upper conductive contact grid (130) coupled with an upperrear conductive pad (142) having a first electric pole (FEP), and a lower side covered by an lower conductive contact grid (132) coupled with a bottom-front conductive pad (140), having a second electric pole (SEP) being opposite to said FEP, wherein each row of the SSCMA includes m solar cells, and each column of the SSCMA includes n solar cells, all of which solar cells are electrically interconnect both in series and in parallel, the method comprising the steps of: providing a continues source of appliable a conductive glue line matter 510; wherein said upper horizontal surface of each said single layer parallel-and-serial connection conductors (252 or 352), except for the first row, is configured to be conductively attached to the respective upper conductive contact grid of the previous solar cell; and wherein said bottom horizontal surface of each said single conductive layer parallel- and-serial connection conductors, except for the last row, is configured to be conductively attached to the respective lower conductive contact grid of the next solar cell; a) providing mXn PV solar cells;b) providing a continues source of appliable a conductive glue line matter (510); c) placing a stack row of m of said solar cells onto a flat surface; d) dispersing a continuous layer of said conductive glue matter (510) on the conductive upper-rear end (+) contact pad ( 142f) of the respective front solar cell lOOf, alongside all strings of adjacent; e) placing the next stack row of m of said solar cells onto a flat surface, wherein the front end of each solar cell is placed over the upper glue layer the respective, previously placed solar cell; f) repeat steps c) and d) until reaching the last stack row of m of said solar cells; and g) placing the nthstack row of m of said solar cells onto a flat surface, wherein the rear end of said lower conductive contact grid (132) of said last placed stack row of m of solar cells is placed over and adjacent to the previously placed row of the m solar cells (100).
15. The method for manufacturing a SSCMA of claim 14, wherein said PV solar cells are regular solar cells.
16. The method for manufacturing a SSCMA of claim 14, wherein said PV solar cells are cut from regular solar cells.
17. A conductive strip of pliable, parallel-and-serial connection conductor (250, 350A, 350B or 510) for interconnecting a pair of rows of solar cells both in parallel and in series, wherein said connection conductor comprises conductive gluey matter.
18. The conductive strip of claim 17, wherein said parallel-and-serial connection conductor conductive gluey matter contains metal.
19. The conductive strip of claim 17, wherein said parallel-and-serial connection conductor comprises further comprises thin conductive conductor layer (252, 352, 354) having a lower surface and an upper surface, and wherein both lower and an upper surfaces are covered with said conductive gluey matter.