Flexible Bypass Substrate Layout for Lightweight Solar Modules
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Solution Overview
Problem
The installation of bypass lines in solar battery panels hinders weight reduction due to the need for bypass diodes and bus bars, which increases system weight and complexity.
Innovation Solution
A solar battery module design featuring a flexible substrate with mounted bypass diodes that forms bypass lines, eliminating the need for a junction box and bus bars, and incorporating flying leads and terminals for output connections, thereby reducing weight and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bypass lines are installed using traditional junction boxes and bus bars, then reliable current bypass is achieved, but system weight increases and complexity increases
Solution Approach 1:
The patent merges the bypass diode mounting function and output line connection function into a single integrated structure. The rear surface substrate serves both as the mounting platform for bypass diodes and as the connection interface for output lines, eliminating the need for separate junction boxes and bus bars, thereby reducing system weight while maintaining bypass reliability
Solution Approach 2:
The rear surface substrate performs multiple functions simultaneously: it serves as a structural support, a mounting base for bypass diodes, and an electrical connection interface for output lines. This multi-functional design reduces the number of components needed and simplifies the overall system structure
2Reliability
If bypass lines are installed using traditional junction boxes and bus bars, then reliable current bypass is achieved, but device complexity increases
Solution Approach 1:
The patent combines multiple components (junction box, bus bars, bypass diodes) into a single integrated rear surface substrate structure, reducing the number of discrete parts and simplifying assembly procedures while maintaining the reliability of current bypass functionality
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (separate junction boxes and bus bars) from the traditional bypass line configuration, keeping only the essential bypass diodes mounted directly on the rear surface substrate, thereby simplifying the system
3Reliability
If traditional bypass line components are used, then current bypass function is achieved, but shadowing effects on solar cells increase
Solution Approach 1:
The patent relocates the bypass diodes from the front surface to the rear surface of the solar battery module, utilizing the unused rear surface area for component placement. This dimensional relocation eliminates shadowing effects on the light-receiving front surface while maintaining the current bypass function
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 design achieves weight reduction and simplifies the system by integrating bypass diodes and output lines on a flexible substrate, reducing the number of components and minimizing shadowing effects on solar cells, leading to increased output efficiency.
Implementation Method 1
A bypass diode is mounted on the flexible substrate. The flexible substrate forms a bypass line of the at least one solar battery panel
Implementation Method 2
A solar battery cell is formed in the at least one solar battery panel
Data Source
AI summary
A solar battery module according to an embodiment has at least one solar battery panel, a flexible substrate and a package. A solar battery cell is formed in the at least one solar battery panel. The flexible substrate is directly or indirectly connected to the at least one solar battery panel. A bypass diode is mounted on the flexible substrate. The flexible substrate forms a bypass line of the at least one solar battery panel. The package accommodates the at least one solar battery panel. The flexible substrate has a base material and a wiring. The wiring is supported by the base material. The wiring has a flying lead and a terminal. The flying lead protrudes from the base material. The flying lead is connected to the at least one solar battery panel. The terminal is provided on an outward side of the package.