Crisscross Solar Sub-Cell Matrix Manufacturing With Reduced Copper
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Solution Overview
Problem
There is a need for production lines capable of manufacturing solar panels with a crisscross matrix array of solar sub-cells, as existing technologies are limited to producing panels with regular solar cells connected in series or parallel configurations, lacking efficient methods for crisscross matrix arrangements.
Innovation Solution
A manufacturing process and system for producing solar panels with a crisscross matrix array of solar sub-cells, involving pre-cutting regular solar cells into sub-cells, placing them on conveyors, and using busbars and conductors to electrically connect them in series and parallel configurations, with reduced conductor diameter or cross-section to enhance panel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If regular solar cells are used with conventional series or parallel connections, then the manufacturing process is simple and well-established, but the panel efficiency and sunlight exposure are limited due to larger conductor usage
Solution Approach 1:
The patent divides regular solar cells into multiple sub-cells (e.g., cutting a 156mm×156mm cell into four 78mm×156mm sub-cells). This segmentation enables the crisscross matrix configuration where fewer conductors are needed to connect the same number of functional photovoltaic units, reducing copper consumption while maintaining or improving power efficiency.
Solution Approach 2:
The patent transitions from conventional one-dimensional series or parallel connections to a two-dimensional crisscross matrix arrangement. This dimensional change allows sub-cells to be interconnected in both horizontal and vertical directions, optimizing conductor placement and reducing the total conductor length required while improving sunlight exposure across the panel surface.
2Use of energy by moving object
If regular solar cells are used with conventional connections, then the manufacturing process is straightforward, but the conductors occupy more space reducing sunlight exposure area
Solution Approach 1:
By segmenting solar cells into smaller sub-cells, the patent reduces the conductor size and cross-section needed for connections. The smaller sub-cells can be arranged more densely in a crisscross pattern, minimizing the space occupied by conductors and maximizing the active sunlight-exposing area of the panel.
Solution Approach 2:
The patent changes the geometric parameters of the solar cell array by dividing cells into sub-cells and arranging them in a crisscross matrix. This parameter change optimizes the ratio of conductor area to active area, reducing conductor dominance and increasing the proportion of sunlight-exposing surface.
3Productivity
If regular solar cells are used with conventional series connections, then the electrical connection process is simple, but the panel cannot achieve optimized power efficiency through crisscross matrix configuration
Solution Approach 1:
The patent introduces a two-dimensional crisscross matrix connection pattern instead of conventional one-dimensional series or parallel arrangements. This dimensional transformation enables optimized power efficiency by creating multiple current paths and reducing resistance, while the underlying manufacturing processes remain fundamentally similar to conventional methods.
Solution Approach 2:
By dividing solar cells into sub-cells and arranging them in a matrix, the patent creates a modular structure that can be manufactured using adapted conventional processes. The segmentation allows for systematic interconnection patterns that improve power efficiency without requiring entirely new manufacturing approaches.
4Loss of substance
If regular solar cells are used, then the panel structure is conventional and easy to manufacture, but reduced conductor usage and enhanced sunlight exposure cannot be achieved
Solution Approach 1:
The patent applies segmentation by cutting regular solar cells into sub-cells, which enables reduced copper consumption through the crisscross matrix configuration. While this adds a cutting step, it utilizes standard industrial cutting equipment and processes, maintaining relative manufacturing simplicity while achieving material reduction.
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
The method reduces copper consumption, increases sunlight exposure, and enhances panel power efficiency by minimizing conductor usage while maintaining equivalent panel dimensions, thus improving electrical connections in a crisscross matrix configuration.
Implementation Method 1
soldering the n×m matrix array of the solar sub-cells with the short parallel jumpers and the wide transverse conductors, to thereby form a soldered SSCA
Implementation Method 2
placing n 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
Implementation Method 3
manufacturing solar panels with a crisscross matrix array of solar sub-cells
Data Source
AI summary
A method for manufacturing a Solar Sub-cells Crisscross matrix Array (SSCA) of solar sub-cells (SSC), wherein each row includes n SSC, and each column includes m SSC, the method includes: placing n×m of SSC onto a narrow sub-cells receptor conveyer belt configured to carry a stream of the SSC; transferring m rows of SSC to a wide array conveyor belt, one row at a time, forming thereon an array of the SSC; placing n busbars or groups of Smart Wire (SW) conductors on each of the n columns of SSC; placing short parallel jumpers between all pairs of neighboring the SSC in each of the m rows; placing wide transverse conductors for parallel connection of the n column and for diodes connection; and soldering the n×m matrix array of SSC with the short parallel jumpers and the wide transverse conductors, to thereby form a soldered SSCA.