Back Contact Foil Bridging for Shape-Adaptive Photovoltaic Modules
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Solution Overview
Problem
Existing photovoltaic modules face challenges in shape adaptation without reducing efficiency, as altering the module's shape often requires redesigning the electrical layout or reconnecting components, which is time-consuming and costly.
Innovation Solution
Incorporating contact bridges outside the single layer back contact substrate to provide electrical connections, allowing for flexible module shaping without affecting the electrical layout or efficiency, enabling the module to be cut to any size or shape without redesigning the back contact substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single layer back contact substrate is used to simplify manufacturing, then ease of manufacture is improved, but adaptability of module shape is worsened
Solution Approach 1:
The electrical connection system is segmented into two independent parts: the single layer back contact substrate for basic electrical connections, and separate contact bridges for additional connectivity. This segmentation allows the substrate to remain simple for manufacturing while contact bridges provide shape adaptability.
Solution Approach 2:
Contact bridges act as intermediary elements that connect the single layer back contact substrate to additional contact points. These bridges enable flexible module shaping by providing additional electrical pathways without requiring redesign of the main substrate.
2Adaptability or versatility
If contact bridges are added outside the back contact substrate, then adaptability of module shape is improved, but device complexity is worsened
Solution Approach 1:
The electrical connection system is segmented into two independent parts: the single layer back contact substrate for basic electrical connections, and separate contact bridges for additional connectivity. This segmentation allows the substrate to remain simple for manufacturing while contact bridges provide shape adaptability.
Solution Approach 2:
The contact bridges provide dynamic adaptability to the module shape without requiring changes to the fixed back contact substrate structure. The bridges can be configured in different arrangements to accommodate various module shapes and sizes.
3Adaptability or versatility
If the electrical layout is redesigned for different module sizes, then adaptability of module shape is improved, but loss of time and manufacturing costs are worsened
Solution Approach 1:
The single layer back contact substrate serves as a universal base structure that can be used across different module configurations. Contact bridges provide the additional flexibility needed for various shapes and sizes, eliminating the need to redesign the entire electrical layout for each configuration.
Solution Approach 2:
The back contact substrate is designed in advance with a universal electrical layout that accommodates multiple module configurations. Contact bridges are added as needed to achieve specific shapes, avoiding time-consuming redesigns for each module variant.
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 solution allows for easy manufacturing and adaptation of photovoltaic module shapes without sacrificing efficiency, maintaining a fixed voltage and allowing for flexible module sizing, reducing manufacturing time and costs while preventing current crowding and shading issues.
Implementation Method 1
a photovoltaic module comprising a plurality of photovoltaic units (3) each having a positive contact terminal (8) and a negative contact terminal (7)
Implementation Method 2
a single layer back contact substrate (4) comprising a positive surface part (6) electrically connected to the positive contact terminal (8) of each of the plurality of photovoltaic units (3), and a negative surface part (5) electrically connected to the negative contact terminal (7) of each of the plurality of photovoltaic units (3)
Implementation Method 3
at least one contact bridge (9a, 9b) in a layer of the photovoltaic module (1) outside of the single layer back contact substrate (4), the at least one contact bridge (9a, 9b) providing an electrical connection in the negative surface part (5) and/or in the positive surface part (6)
Data Source
AI summary
A photovoltaic module (1) with a plurality of photovoltaic units (3) each having a positive contact terminal (8) and a negative contact terminal (7), and a single layer back contact substrate (4). The back contact substrate (4) has a positive surface part (6) electrically connected to the positive contact terminal (8) of each of the plurality of photovoltaic units (3), and a negative surface part (5) electrically connected to the negative contact terminal (7) of each of the plurality of photovoltaic units (3). The photovoltaic module (1) further has at least one contact bridge (9a, 9b) in a layer of the photovoltaic module (1) outside of the single layer back contact substrate (4), which provides an electrical connection in the negative surface part (5) and/or in the positive surface part (6).