Monolithic Micro-Inverter Integration in Thin Film Solar Modules
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Solution Overview
Problem
The high cost of installing multiple maximum power point tracking (MPPT) devices in solar cell systems outweighs their efficiency benefits, and existing solar module designs face challenges in maximizing power output due to variability in solar cell diodes and shading issues, leading to reduced overall performance.
Innovation Solution
Integrating power conversion electronics directly into thin film solar cell manufacturing, using amorphous InGaZnO (a-IGZO) for higher mobility and efficiency, and monolithically combining thin film solar cells with electronic conversion units and microcontrollers to form a single substrate circuit, enabling enhanced system performance at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple MPPT devices are installed in solar arrays, then power output efficiency is improved, but system installation costs increase
Solution Approach 1:
The patent combines the solar cell diode and electronic conversion unit (ECU) onto a single substrate, integrating the power conversion functionality directly with the solar cell. This merging eliminates the need for separate MPPT devices while maintaining efficiency, as the integrated ECU performs maximum power point tracking inherently through its design with the solar cell diode
Solution Approach 2:
The integrated substrate serves multiple functions simultaneously: it acts as both the solar cell substrate and the electronic circuit board housing the ECU. This multi-functional design allows the single substrate to replace multiple separate components (solar cell, MPPT device, power converter), reducing system complexity and installation costs while maintaining productivity
2Stress or pressure
If solar cells are connected in series to obtain desired voltage, then voltage requirement is met, but power loss increases due to diode variability and shading
Solution Approach 1:
The patent divides the solar array into independent modular units, each consisting of a solar cell diode integrated with its own ECU on a single substrate. This segmentation allows each module to operate independently with its own MPPT, preventing power loss from propagating through the entire series connection due to diode variability or shading of individual cells
Solution Approach 2:
Each integrated substrate is optimized locally with its own ECU designed specifically for that solar cell diode's characteristics. This local optimization allows each module to independently track its maximum power point and compensate for local variations in diode performance or shading conditions, reducing overall power loss while meeting voltage requirements through series connection of optimized modules
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 optimizes solar array performance by reducing system assembly efforts and costs, while maximizing power output through integrated MPPT and power conversion capabilities at the solar cell level, minimizing the impact of diode variability and shading effects.
Implementation Method 1
Solar cells are photovoltaic devices which convert sunlight into electricity
Implementation Method 2
CIGS material strongly absorbs sunlight such that a much thinner film is required
Data Source
AI summary
Embodiments of the present invention include a method for manufacturing, and a structure for a thin film solar module. The method of manufacturing includes fabricating a thin film solar cell and fabricating an electronic conversion unit (ECU) on a single substrate. The thin film solar cell has at least one solar cell diode on a substrate. The ECU has at least one transistor on the substrate. The ECU may further comprise a capacitor and an inductor. The ECU is integrated on the substrate monolithically and electrically connected with the thin film solar cell. The ECU and the thin film solar cell interconnect to form a circuit on the substrate. The ECU is electrically connected to a microcontroller on the solar cell module.