Mosaic Solar Cell Assembly Layout for High Fill Factor
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Solution Overview
Problem
The inefficiency in using circular solar cell wafers for solar arrays due to low fill factor and waste in cutting them into rectangular shapes, leading to increased costs and reduced space utilization in space applications, where high efficiency and robust interconnections are critical.
Innovation Solution
A method of fabricating mosaic solar cell assemblies by scribing circular wafers into discrete polygonal elements, rearranging, and connecting them in a closely packed manner over a rectangular template, maximizing wafer utilization and packing factor, with interconnects placed on one edge for efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If circular wafers are cut into rectangular solar cells to achieve high fill factor, then space utilization is improved, but wafer material waste increases
Solution Approach 1:
The circular wafer is divided into multiple discrete mosaic elements (typically 4-8 segments) that can be independently arranged and reconfigured. This segmentation allows the wafer material to be fully utilized while creating rectangular or polygonal elements with high fill factor when assembled together.
Solution Approach 2:
Multiple mosaic elements from a single circular wafer are nested and arranged within a rectangular assembly footprint, allowing the circular wafer material to be efficiently packed into a rectangular configuration that maximizes space utilization while minimizing waste.
2Loss of substance
If circular solar cells are used to minimize wafer waste, then material utilization is improved, but array fill factor decreases
Solution Approach 1:
The circular wafer is segmented into multiple pieces that can be rearranged into rectangular or polygonal configurations. This allows the material to be fully utilized from the circular wafer while the resulting elements pack efficiently into rectangular arrays, achieving both high material utilization and high fill factor.
Solution Approach 2:
The solution transitions from using complete circular solar cells to using segmented portions of circular wafers arranged in a two-dimensional rectangular pattern. This dimensional reconfiguration allows simultaneous optimization of both material utilization (from circular wafer) and space efficiency (rectangular array layout).
3Area of moving object
If multiple discrete solar cells are assembled into an array, then space utilization is improved, but the number of interconnections increases
Solution Approach 1:
Multiple mosaic elements from a single wafer are electrically interconnected as a unified module or assembly. This merging reduces the total number of interconnections required compared to using separate commercial solar cells, as the mosaic elements are already electrically integrated through the wafer structure and can be connected to external circuits through fewer terminal points.
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 enhances power density and reduces material waste, achieving a high fill factor and efficient use of space while minimizing the number of interconnections, thus lowering production costs and improving the efficiency of solar cell arrays for space applications.
Implementation Method 1
Photovoltaic devices, such as photovoltaic modules or CIC (solar Cell + Interconnects + Cover glass) assemblies, comprise one or more individual solar cells arranged to produce electric power in response to irradiation by solar light
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2E
AI summary
A method of producing a solar cell assembly comprises the steps of: providing at least one solar cell wafer (100; 200; 300; 350); cutting each wafer into a plurality of mosaic elements (101, 102, 103; 201-215; 301-304; 360-363; 371-374; 381-383; 391-393); arranging a plurality of the mosaic elements one after the other along a first axis, so that the mosaic elements form a row of mosaic elements, each mosaic element having substantially the same height in a direction perpendicular to the first axis; providing each mosaic element with a conductive interconnect (104-107; 251; 252; 341-344; 375; 385; 395) at a first end thereof, so that the solar cell assembly can be electrically connected to an adjacent solar cell assembly; and bonding the mosaic elements to a cover glass.