Monolithic Thin-Film Solar Module With Integrated Controller
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Solution Overview
Problem
Existing solar cell technologies require additional electronic components for efficient charging of batteries, leading to increased production costs and complexity, and existing integrated devices lack the integration of all necessary components in a single monolithic thin-film fabrication process.
Innovation Solution
A thin-film integrated device comprising a solar cell, an energy storage device, and an electronic controller built monolithically on a single substrate, with electrical connections via vias, eliminating the need for external components and allowing for reduced size and cost while ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional electronic components are integrated into the solar cell system to enable efficient battery charging and power management, then the functionality and reliability of the system is improved, but the device complexity and production cost increase
Solution Approach 1:
The patent merges the solar cell, energy storage device, and electronic controller into a single monolithically integrated thin-film device. All components are fabricated on one substrate using sequential thin-film deposition processes, combining multiple functional elements into one unified structure that reduces complexity while maintaining reliability.
Solution Approach 2:
The integrated device performs multiple functions within a single structure: the solar cell generates electricity, the energy storage device stores energy, and the electronic controller manages power flow and implements maximum power point tracking. This multi-functionality eliminates the need for separate external components.
2Ease of manufacture
If multiple separate components are used to build an integrated solar-battery system, then the ease of manufacture is improved, but the final device size and integration density increase
Solution Approach 1:
The patent transitions from planar integration to three-dimensional vertical stacking, with the solar cell, energy storage device, and electronic controller arranged in vertical layers on a single substrate. This vertical arrangement achieves high integration density and compact form factor while maintaining ease of manufacture through sequential thin-film deposition processes.
3Ease of manufacture
If a monolithic thin-film fabrication process is used to integrate all components, then the production cost and device size are reduced, but the manufacturing precision and process complexity increase
Solution Approach 1:
The monolithic fabrication process is segmented into distinct sequential stages: first depositing the solar cell thin films, then the energy storage device thin films, and finally the electronic controller thin films. Each stage uses appropriate deposition techniques and can be independently optimized, allowing high manufacturing precision to be achieved despite the complex overall process.
4Adaptability or versatility
If external electronic components are used for power management, then the adaptability of the system is improved, but the production cost and device complexity increase
Solution Approach 1:
The electronic controller integrated within the device provides multiple functions including maximum power point tracking, voltage regulation, and battery management. This integrated approach maintains system adaptability while reducing complexity by eliminating external components and interconnections.
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
The solution enables a compact, cost-effective, and reliable solar module that can operate autonomously, charge batteries during the day, and provide power at night, with integrated maximum power point tracking for optimal energy output, reducing production costs and enhancing reliability.
Implementation Method 1
Solar cells are photovoltaic devices which convert sunlight into electricity
Data Source
AI summary
A thin-film monolithically integrated solar module with a solar cell, an integrated energy storage device, and a controller may be provided. It may comprise a thin-film solar cell, having at least one solar diode, on a transparent substrate, a thin-film energy storage device, and an electronic controller comprising at least one thin-film transistor above the thin-film energy storage device. The electronic controller may be electrically connected to the thin-film solar cell and the thin-film energy storage device by vias. The named functional units may build a monolithically integrated device on one substrate.