Corrugated Shingled Solar Cell Ribbons Without Inter-Cell Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional solar cell arrangements require gaps between cells for ribbon connections, reducing the effective power generation area and introducing resistive losses.
Innovation Solution
Shingled solar cells with corrugated shapes and overlapping protrusions and recessions, connected in series by conductive ribbons that pass through openings, eliminating gaps and reducing resistive losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional solar cell arrangements with gaps are used for ribbon connections, then electrical connection between cells is achieved, but the effective power generation area is reduced
Solution Approach 1:
The ribbon is nested within the recessing portions of the corrugated cell edges, allowing the electrical connection to be integrated within the cell structure itself rather than requiring separate gap spaces. The ribbon passes through the recessing portions and connects to busbars, effectively hiding the connection mechanism within the cell's own geometry.
Solution Approach 2:
The corrugated edge profile adds a third dimension (depth) to the cell edge, creating recessing portions that provide space for ribbon integration. This dimensional change allows the ribbon to be positioned within the cell structure rather than requiring lateral gap space between cells.
2Loss of energy
If traditional solar cell arrangements with gaps are used, then ribbon connections can be made, but resistive losses increase
Solution Approach 1:
The corrugated shape with recessing portions is pre-formed on the cell edges before assembly, creating built-in pathways for ribbon insertion. This preliminary structuring simplifies the assembly process by providing predetermined routing paths that guide ribbon placement and reduce manufacturing complexity.
Solution Approach 2:
The corrugated profile creates localized recessing portions at specific regions of the cell edges where ribbon connections are needed. This local structural modification provides optimized connection points with reduced contact resistance while maintaining flat surfaces in other areas for efficient light absorption.
3Productivity
If shingled arrangement with corrugated shapes is used, then space utilization is maximized, but manufacturing complexity increases
Solution Approach 1:
The cell edge is segmented into protruding portions and recessing portions through the corrugated profile, allowing different functional zones. The recessing portions handle electrical connections while the protruding portions maintain optical efficiency, dividing the edge structure into functionally optimized segments.
Solution Approach 2:
The corrugated profile introduces controlled curvatures and rounded transitions between protruding and recessing portions, which simplifies manufacturing compared to sharp angular features while maintaining the space-saving shingled arrangement functionality.
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
Enhances power generation efficiency by maximizing space utilization and minimizing resistive losses, simplifying manufacturing, and reducing material waste.
Implementation Method 1
The shingled solar cells are electrically connected in series by an electrically conductive ribbon which passes through an opening created a recessing portion to electrically connect the rear surface metallization of one cell with the front surface metallization of an adjacent cell
Implementation Method 2
Each solar cell has at least one long edge having a corrugated shape, where the corrugated shape comprises protruding portions and recessing portions. The solar cells in the string are arranged in a shingled manner with the protruding portions of one cell overlapping with an adjacent solar cell.
Implementation Method 3
The doped regions are connected to conductive regions on the solar cell to direct an electrical current from the cell to an external circuit
Data Source
AI summary
A string of solar cells is disclosed. The sides of the solar cells have a corrugated shape which forms an opening when the solar cells are arranged in a shingled manner. The solar cells are electrically connected in series by a ribbon that passes through the opening. A wire mesh used to decrease solar cell resistance is also disclosed.