Back-Contact PV Cell Wiring Layout With Hidden Ribbon Crossovers
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Solution Overview
Problem
The efficient electrical interconnection of photovoltaic cells with back side contacts into a string is complex and requires a method that minimizes production complexity and maintains aesthetic appeal by hiding wiring elements from the front face.
Innovation Solution
A method involving the arrangement of photovoltaic cells with rotated orientations and overlaps, with elongated wiring elements placed in specific lateral positions to connect cells in series, allowing for straight crossovers and minimizing visible wiring, using a device with a platform and depositing means to manage the wiring elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If photovoltaic cells are arranged with rotated orientations and overlaps, then the wiring elements can be hidden from the front face improving aesthetic appearance, but the production complexity increases due to the complex arrangement and interconnection requirements
Solution Approach 1:
The photovoltaic module is divided into multiple strings, with each string containing a specific number of cells (e.g., 6 cells per string) arranged in a predetermined pattern. This segmentation allows the complex wiring task to be broken down into manageable, repetitive units that can be produced efficiently.
Solution Approach 2:
Cells within each string are arranged with alternating orientations (some cells rotated 180 degrees relative to others) and overlapping positions. This asymmetric arrangement creates a zigzag wiring path that keeps conductive ribbons hidden on the back surface while maintaining aesthetic appearance from the front.
Solution Approach 3:
The method establishes a predetermined arrangement pattern for cells and wiring elements before actual production. By pre-defining the alternating orientations, overlap positions, and wiring paths, the complex task is simplified into a repeatable process that reduces production complexity.
2Length of moving object
If cells are arranged with overlaps, then the module length is reduced while maintaining optical surface area, but the wiring path becomes more complex requiring precise positioning
Solution Approach 1:
Overlap positions and dimensions are predetermined in the design phase, establishing fixed reference points for cell placement and wiring routing. This pre-planning ensures that wiring elements follow consistent, predictable paths through the overlaps, reducing the need for complex real-time positioning adjustments during manufacturing.
Solution Approach 2:
The wiring elements are routed through the third dimension by placing them on the back surface of cells and using vertical overlaps to create natural wiring channels. This dimensional approach allows wiring to pass through overlap regions without requiring precise lateral positioning, as the vertical stacking provides inherent alignment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient and aesthetically pleasing photovoltaic module production by reducing light reflections and maintaining a uniform appearance while ensuring effective electrical interconnection of cells.
Implementation Method 1
photovoltaic cells having back side contacts have their electrodes on the back face i.e. the side opposite the side which faces primarily the sun. This type of photovoltaic cells provides a superior efficiency in comparison to regular photovoltaic having their electrodes on the front and on the back face.
Data Source
AI summary
The present disclosure relates to a method and a device for wiring photovoltaic cells into a string of photovoltaic cells, as well as a module comprising a string of photo voltaic cells. The photovoltaic cells are typically arranged in a first direction and are electrically interconnected by elongated wiring elements on their respective back faces in series.