High-Voltage Solar Module Layout With Monolithic Sub-Cell Interconnects
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Solution Overview
Problem
Conventional solar cell modules face challenges in achieving high voltage outputs without increasing module interconnections or handling complexity, and they often require power electronics for efficient energy conversion.
Innovation Solution
The approach involves dicing solar cells into smaller sub-cells and using metallization as a handle for singulation, allowing for flexible module current and voltage configurations, with a monolithic metallization structure providing mechanical integrity and built-in strain relief, and using encapsulants to prevent shunting and wear, thereby eliminating the need for additional interconnects and power electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional solar modules use standard interconnection methods, then module assembly is straightforward, but achieving high voltage outputs requires increasing the number of interconnections which increases complexity
Solution Approach 1:
The solar cell is divided into multiple sub-cells through dicing, with each sub-cell having its own metallization structure. This segmentation allows the cell to function as multiple series-connected units, achieving high voltage output without requiring additional interconnections between separate cells. The monolithic structure maintains electrical continuity while providing mechanical separation for strain relief.
Solution Approach 2:
The metallization structure serves dual functions: it provides electrical interconnection between sub-cells and simultaneously acts as a mechanical back-stop during dicing and provides strain relief. This merging of electrical and mechanical functions reduces the need for separate interconnection components and simplifies the overall module architecture.
2Adaptability or versatility
If solar cells are diced into smaller sub-cells, then voltage configurations become flexible, but handling and assembly complexity increases
Solution Approach 1:
The metallization structure is formed on the solar cell substrate before dicing into sub-cells. This preliminary metallization ensures that electrical connections are already established and will remain intact during subsequent handling and assembly processes. The pre-formed metallization acts as a mechanical handle that facilitates controlled dicing while maintaining structural integrity.
Solution Approach 2:
The monolithic metallization structure serves as an intermediary that provides both electrical connectivity and mechanical support during the dicing process. It acts as a back-stop that prevents substrate breakage while enabling the creation of physically separated sub-cells with maintained electrical connections, simplifying subsequent module assembly.
3Power
If additional interconnects are used to achieve high voltage, then voltage output increases, but reliability decreases due to more potential failure points
Solution Approach 1:
The electrical interconnection function and mechanical support function are merged into a single monolithic metallization structure. This eliminates the need for separate interconnect components that would create additional potential failure points. The integrated structure provides both high voltage capability through series connection of sub-cells and enhanced reliability by reducing the number of discrete components.
4Productivity
If power electronics are included for voltage conversion, then energy conversion efficiency improves, but device complexity and cost increase
Solution Approach 1:
The solar cell itself performs the voltage conversion function through its monolithic multi-subcell structure, eliminating the need for external power electronics. The cell's internal series-connected sub-cells generate high voltage directly, making the system self-sufficient and removing complex voltage conversion requirements. This self-service approach maintains efficiency while dramatically reducing system complexity.
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 method enables the creation of high voltage modules with reduced complexity and increased reliability, scalability, and efficiency, allowing for the simplification or elimination of power electronics in inverters and optimizers, while maintaining mechanical and electrical integrity.
Implementation Method 1
Photovoltaic (PV) cells, commonly known as solar cells, are well known devices for conversion of solar radiation into electrical energy
Data Source
AI summary
A photovoltaic module can include a high voltage photovoltaic laminate that include a plurality of high voltage photovoltaic cells with each of the high voltage photovoltaic cells including a plurality of sub-cells. A boost-less conversion device can be configured to convert a first voltage from the high voltage photovoltaic laminate to a second voltage.