Curved Shingled Solar Module Layout That Protects Half-Cut Cell Edges
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Solution Overview
Problem
In solar cell modules arranged in a shingling structure on a curved surface, the cut ends of half-cut solar cells experience high local pressurizing stress during the sealing process, leading to potential breakage and reduced efficiency due to micro-cracks caused by laser irradiation.
Innovation Solution
The solar cells are arranged such that the edge of the non-cut end of one solar cell contacts the concave-side main surface of an adjacent solar cell, while the cut end remains non-contact, reducing the load on the cut end and minimizing the risk of cracking and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If half-cut solar cells are arranged in a shingling structure on a curved surface, then more solar cells can be mounted on a limited area and light receiving area is increased, but the cut ends are subjected to large local pressurizing stress during sealing which causes breakage
Solution Approach 1:
The patent inverts the conventional shingling arrangement by making the non-cut ends overlap instead of the cut ends. Specifically, the non-cut end of a solar cell in a lower row overlaps the concave-side main surface of a solar cell in an upper row, while the cut end is positioned on the convex side where it does not contact adjacent cells. This inversion protects the vulnerable cut ends from sealing pressure while maintaining the space-efficient shingling structure.
Solution Approach 2:
The patent applies different functional characteristics to different parts of the solar cell arrangement. The non-cut ends are designed to overlap and contact during sealing, providing structural stability and stress distribution, while the cut ends are positioned on the convex side to avoid contact and sealing pressure. This local differentiation of contact zones protects the vulnerable cut ends while maintaining effective sealing at the robust non-cut ends.
2Adaptability or versatility
If solar cells are arranged with overlapping edges on a curved surface, then the module can be formed on curved surfaces, but the overlapping portions only contact locally on an edge which increases thickness and requires large sealing load
Solution Approach 1:
The patent inverts which ends overlap by having non-cut ends overlap instead of cut ends. This inversion allows the overlapping portion to have a larger contact area since the non-cut ends provide a broader sealing surface compared to edge-only contact, thereby reducing the sealing load required while maintaining curved surface adaptability.
3Stability of the object's composition
If cut ends are positioned to contact in shingling arrangement, then consistent overlapping pattern is achieved, but micro-cracks at cut ends lead to reduced efficiency and breakage
Solution Approach 1:
The patent inverts the overlap configuration to have non-cut ends overlap instead of cut ends. This ensures that the vulnerable cut ends with potential micro-cracks are positioned on the convex side where they do not contact adjacent cells or undergo sealing pressure, thereby preventing crack propagation and maintaining cell efficiency while still achieving a consistent overlapping pattern.
Solution Approach 2:
The patent applies different functional roles to different ends of the solar cells. The non-cut ends serve as the overlapping contact zones for structural stability and sealing, while the cut ends are positioned in non-contact zones to avoid stress concentration. This local functional differentiation protects the efficiency-critical cut ends from mechanical degradation.
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 arrangement suppresses the application of large loads to the cut ends, preventing breakage and maintaining the integrity and efficiency of the solar cell module, thereby enhancing its reliability and output.
Implementation Method 1
increases a light receiving area for photoelectric conversion and improves output of the solar cell module
Data Source
AI summary
A solar battery module capable of suppressing a large load from being applied on a cut end section of a solar battery cell. This solar battery module has a curved surface shape and comprises flat solar battery cells arranged using a singling method. Each of the solar battery cells is a half-cut cell obtained by cutting a predetermined-sized substrate into two pieces, has a cut end section and a non-cut end section as two end sections facing each other in the arrangement direction of the solar battery cells, and has, as two main surfaces, a convex-side main surface on the convex side of a curved surface of the solar battery module and a concave-side main surface on the concave side of the curved surface of the solar battery module. The solar battery cells adjacent to each other overlap.