Meandering Back-Side Contact for PV Module Bypass Diodes
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Solution Overview
Problem
The existing back side connection layers for photovoltaic modules face challenges in efficiently accommodating by-pass diodes due to limited space between adjacent cells, leading to high power dissipation and reduced module performance under shaded conditions, as the narrow conductive paths required to carry current result in significant power loss.
Innovation Solution
The solution involves optimizing the layout of the back side contact layer by adjusting the placement and width of the by-pass diode connection path, allowing for a more efficient layout with a predetermined minimal width and meandering pattern that increases the available space for the conductive path, ensuring adequate current carrying capacity without excessive power dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the back side contact layer uses a narrow conductive path to accommodate limited space between adjacent cells, then the space utilization is improved, but the power dissipation increases and module performance deteriorates under shaded conditions
Solution Approach 1:
The patent transitions from a two-dimensional planar layout to a three-dimensional configuration by creating a meandering path that utilizes the vertical dimension and available space more effectively. The meandering connection path allows the conductor to navigate around obstacles and utilize space in multiple dimensions rather than being constrained to a straight line, thereby achieving both compact space utilization and adequate current carrying capacity
Solution Approach 2:
The patent employs a meandering (curved) connection path instead of a straight conductive path. This curvature allows the conductor to follow the available space between adjacent cells more efficiently, increasing the effective length and cross-sectional area of the conductive path without requiring additional horizontal space, thus reducing power dissipation while maintaining compact layout
2Loss of energy
If the by-pass diode connection path is made wider to reduce power dissipation, then the current carrying capacity is improved, but the available space between adjacent cells is exceeded
Solution Approach 1:
The patent divides the by-pass diode connection path into multiple segments or sections that follow a meandering pattern. This segmentation allows the total conductive path to achieve the required effective width and current carrying capacity by distributing the conduction across multiple segments rather than requiring a single wide straight path, thereby fitting within the limited space between adjacent cells
Solution Approach 2:
The meandering path utilizes the vertical dimension and available space between cells more effectively, allowing the connection path to achieve adequate current carrying capacity through increased path length and optimized routing in three-dimensional space rather than requiring excessive horizontal width
3Productivity
If the outer contacts are positioned closer to the cell edge to maximize space utilization, then the layout efficiency is improved, but the space for by-pass diode connection path is reduced
Solution Approach 1:
The meandering connection path with its curved segments is designed to navigate around the outer contacts positioned near the cell edges. The curvature allows the conductor to follow the available space contours, achieving adequate connection path width while maintaining high layout efficiency with outer contacts close to the edges
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 approach enables a wider by-pass diode connection path, reducing power dissipation and enhancing the performance of photovoltaic modules under shaded conditions by minimizing losses and allowing for more efficient current flow, thereby improving the overall efficiency and reliability of the module.
Implementation Method 1
a by-pass diode connection path (6) having a predetermined minimal width (w) is formed in the back side connection layer (3) along an edge direction of two adjacent cells (1, 2)... allowing for a more efficient layout with a predetermined minimal width and meandering pattern that increases the available space for the conductive path, ensuring adequate current carrying capacity without excessive power dissipation
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Back side connection layer for a photo-voltaic module with a plurality of PV-cells (1, 2). The PV-cells (1, 2) are of a type having a plurality of back side contacts (11, 12). A by-pass diode connection path (6) is formed in the back side connection layer (3) along an edge direction of two adjacent cells (1, 2) with a straight or meandering pattern around outer contacts (4, 5) of the plurality of back side contacts (11, 12) of the two adjacent cells (1, 2).