Foldable Photovoltaic Assembly Non-Perpendicular Interconnection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional foldable photovoltaic assemblies experience significant fatigue and reduced lifespan due to perpendicular conductive interconnection structures, which fail after a limited number of folding cycles, limiting their usability and durability.
Innovation Solution
The implementation of a non-perpendicular conductive interconnection structure within fold zones, where conductors extend at an angle relative to the fold line, reduces internal stress and allows for repeated folding and unfolding without causing fatigue, thereby increasing the assembly's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perpendicular conductive interconnection structures are used to connect PV submodules, then electrical connectivity is achieved, but the assembly experiences significant fatigue and reduced lifespan after limited folding cycles
Solution Approach 1:
The patent applies asymmetry by changing the orientation angle of conductive interconnection structures from perpendicular (90 degrees) to non-perpendicular angles (e.g., 45 degrees). This asymmetric modification to the interconnection structure's geometry reduces internal stress concentration during folding, thereby extending the assembly's lifespan and durability through thousands of folding cycles without failure.
2Strength
If perpendicular conductive interconnection structures are used, then manufacturing simplicity is maintained, but internal stress causes fatigue and interconnection failure
Solution Approach 1:
The patent applies parameter changes by modifying the orientation angle parameter of conductive interconnection structures from 90 degrees (perpendicular) to non-perpendicular angles such as 45 degrees. This parameter modification reduces internal stress and fatigue during folding operations, significantly improving interconnection durability while maintaining manufacturing feasibility through standard fabrication processes.
3Ease of operation
If foldable PV assemblies are designed for portability, then ease of operation is improved, but perpendicular interconnection structures fail after limited folding cycles
Solution Approach 1:
The patent applies asymmetry by orienting conductive interconnection structures at non-perpendicular angles (e.g., 45 degrees) relative to the fold line, rather than perpendicular to it. This asymmetric configuration reduces stress concentration during folding operations, enabling the portable foldable PV assembly to maintain interconnection reliability over thousands of folding cycles while preserving portability and ease of operation.
Data Source
AI summary
Foldable photovoltaic assemblies and methods of manufacturing such assemblies, including a transparent top sheet having a fold line and a conductive interconnection pattern spanning the fold line. The conductive interconnection pattern includes inter-cell connections configured to interconnect individual photovoltaic cells to form photovoltaic submodules, and also inter-submodule connections configured to interconnect photovoltaic submodules to form an assembly of submodules, which in some cases may be a fully assembled photovoltaic module. The inter-submodule connections span the fold line and are oriented at non-perpendicular angles relative to the fold line.