Five-Strip Solar Module Strings With Bypass Diode Protection
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Solution Overview
Problem
Solar panels are costly due to the expensive photovoltaic silicon wafer materials and face challenges in efficient large-scale manufacturing, limiting their widespread adoption and competitiveness with traditional energy sources.
Innovation Solution
A high-density solar module manufacturing method using diode protection and a configuration of five strips, where three inner strips are separated from a photovoltaic substrate, and two strips are not included, allowing for efficient by-pass diodes to maintain electrical current generation even when one strip is shaded, and utilizing overlapped or tiled photovoltaic strip elements to reduce series resistance losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional photovoltaic silicon wafer materials are used, then solar panels can generate electricity from sunlight, but the manufacturing cost is high and large-scale manufacturing efficiency is limited
Solution Approach 1:
The solar module is divided into multiple parallel strings, each string containing multiple photovoltaic cells connected in series. This segmentation allows for modular manufacturing and assembly, improving both manufacturing efficiency and electrical performance
Solution Approach 2:
Multiple parallel strings are combined within a single module frame, creating a high-density configuration that increases power output per module while maintaining compatibility with standard mounting systems
2Use of energy by moving object
If photovoltaic panels are used to convert sunlight into electricity, then renewable energy generation is achieved, but the cost remains high compared to traditional energy sources
Solution Approach 1:
The module design changes key parameters including string configuration, cell arrangement, and electrical connections to optimize performance-to-cost ratio while maintaining renewable energy conversion capability
3Productivity
If solar modules are designed with higher density configurations, then manufacturing efficiency and cost-effectiveness improve, but electrical performance and reliability may be compromised
Solution Approach 1:
The module is segmented into multiple parallel strings with defined electrical connections, allowing for optimized cell arrangement that improves manufacturing efficiency while maintaining electrical performance through proper series-parallel configuration
Solution Approach 2:
Busbars and connection elements serve as intermediaries between photovoltaic cells and external circuits, enabling efficient current collection and transfer while maintaining electrical integrity in high-density configurations
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 results in a more efficient and cost-effective solar module design that can be manufactured using conventional processes, maintaining industry standard sizes and electrical characteristics while maximizing performance and reducing manufacturing costs.
Implementation Method 1
a plurality of photovoltaic strips forming each of the plurality of photovoltaic strings
Data Source
AI summary
In an example, the present invention provides a method of manufacturing a solar module. The method includes providing a substrate member having a surface region, the surface region comprising a spatial region, a first end strip comprising a first edge region and a first interior region, the first interior region comprising a first bus bar, a plurality of strips, a second end strip comprising a second edge region and a second interior region, the second edge region comprising a second bus bar, the first end strip, the plurality of strips, and the second end strip arranged in parallel to each other and occupying the spatial region such that the first end strip, the second end strip, and the plurality of strips consists of a total number of five (5) strips. The method includes separating each of the plurality of strips, arranging the plurality of strips in a string configuration, and using the string in the solar module.