Graphene Electrode Photovoltaic Module Bus Bar Elimination

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Solution Overview

Problem

Photovoltaic modules using traditional 'bus bar' technology suffer from inefficiencies, durability issues, and sensitivity to weather conditions, leading to energy losses due to micro-cracks and shading effects, as well as high material costs and limited lifespan.

Innovation Solution

The use of graphene electrodes in the form of a network or strips applied directly to both sides of photovoltaic cells within a polymer foil, eliminating the need for soldering and traditional bus bars, thereby enhancing durability, reducing material costs, and improving energy efficiency by better handling scattered light and temperature variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional bus bar technology is used to connect photovoltaic cells, then the electrical connection is established, but energy losses amount to up to 3-5% due to micro-cracks and shading effects

Engineering Contradiction:

Improveenergy lossVSAvoidconnection structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent removes the traditional bus bar connection structure from the photovoltaic module. By extracting this problematic component, the invention eliminates the source of micro-cracks and shading effects that caused 3-5% energy losses, while maintaining electrical connectivity through an alternative integrated design

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the electrical connection function with the encapsulant material itself. The encapsulant is formulated to provide both mechanical protection and electrical conductivity, combining multiple functions into a single integrated component that eliminates the need for separate bus bars

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional bus bar technology is used, then electrical connection is achieved, but durability is reduced due to sensitivity to weather conditions and temperature variations

Engineering Contradiction:

ImprovedurabilityVSAvoidweather sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a composite encapsulant material that combines polymer matrix with conductive fillers. This composite structure provides both mechanical durability against weather conditions and electrical conductivity, creating a single material that resists environmental degradation while maintaining electrical performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of the encapsulant material to enhance its performance. By adjusting composition, cross-linking density, and conductive particle distribution, the material achieves optimal balance between durability, conductivity, and weather resistance

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If traditional bus bar technology is used, then cell connections are made, but material costs increase and lifespan is limited

Engineering Contradiction:

Improvemodule lifespanVSAvoidmaterial usage

Core Design Contradiction:

Duration of action of stationary objectVSQuantity of substance

Solution Approach 1:

The patent replaces expensive precious metal bus bars with a cost-effective polymer-based conductive encapsulant. This substitution uses abundant, inexpensive materials to achieve the same electrical connection function, significantly reducing material costs while improving longevity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The encapsulant material performs multiple functions simultaneously: mechanical protection, electrical insulation/conduction, environmental sealing, and structural support. This multi-functionality eliminates the need for separate bus bar components, reducing overall material usage and extending module lifespan

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution increases energy production by over 50% while minimizing losses due to shading and micro-cracks, extends module lifespan, and reduces material usage, with improved thermal conductivity and resistance to micro-fractures, resulting in higher overall system efficiency and reduced manufacturing costs.

Implementation Method 1

connecting individual cells with a graphene electrode in form of graphene network or graphene strips set in the polymer foil

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

improving energy efficiency by better handling scattered light

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 3

resistance to micro-fractures

Methodology Applied

Scientific EffectStress distribution:

Implementation Method 4

graphene strips set in the polymer foil applied directly on both the cell on the exposed side as well as from the bottom

Methodology Applied

Scientific EffectEncapsulation:

Data Source

PatentUS20230178671A1Photovoltaic module

Publication Date: 2023.06.08 FREEVOLT SA

AI summary

A photovoltaic module is shown. The module is made up of a set of cells. Each cell comprises silicon while a graphene electrode is used for the connections. The electrode comprises a graphene grid or strips and is set in a polymer layer applied to the cells from both sides.