Parallel Wire Network for PV Cell Interconnection
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Solution Overview
Problem
Photovoltaic modules face challenges in current collection and interconnection due to parasitic series resistances, affecting efficiency and reliability, which are critical for the performance, cost-effectiveness, and viability of renewable energy sources.
Innovation Solution
A novel interconnect wire network assembly using conductive wires with electrically insulating carrier films, where the wires are parallel to each other and attached to the front and back sides of photovoltaic cells, allowing for series electrical connections and closer cell arrangements, improving current distribution and collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional electrical connections are used to interconnect photovoltaic cells, then current collection is achieved, but parasitic series resistances increase reducing efficiency
Solution Approach 1:
The patent divides the current collection function into multiple parallel conductive portions (fingers) that are distributed across the photovoltaic cell surface. This segmentation reduces the current density in each individual conductor, thereby reducing I²R losses and parasitic series resistance effects while maintaining reliable current collection across the entire module.
Solution Approach 2:
The patent introduces conductive gels or pastes as intermediary materials between the conductive portions and the photovoltaic cell contacts. These intermediary materials improve the electrical connection quality, reduce contact resistance, and minimize parasitic series resistance losses while enhancing the reliability of the interconnection.
2Productivity
If cells are arranged closer together in a module, then module density increases, but electrical insulation between adjacent cells becomes more difficult
Solution Approach 1:
The patent uses insulating carrier films as intermediary layers between adjacent conductive portions. These carrier films provide electrical insulation that prevents short circuits between neighboring cells, enabling closer cell arrangements while maintaining proper electrical isolation. The carrier films act as mediators that allow high cell density without compromising insulation.
Solution Approach 2:
The patent employs thin film carrier films that are flexible and can be precisely positioned between conductive portions. These thin films provide the necessary electrical insulation for close cell spacing while occupying minimal space, thus enabling high module cell density without electrical interference between adjacent cells.
3Reliability
If multiple conductive portions are used for current collection, then current distribution improves, but device complexity increases
Solution Approach 1:
The patent designs the conductive portions with carrier films as multi-functional components that simultaneously provide electrical conduction, mechanical support, and electrical insulation. This multi-functionality allows multiple conductive portions to achieve uniform current distribution while the shared carrier film structure reduces overall device complexity by eliminating the need for separate insulation components.
Data Source
AI summary
Provided are novel interconnect wire network assemblies and methods of fabricating thereof. An assembly may include conductive portions/individual wires that, in certain embodiments, are substantially parallel to each other. The assembly also includes two or more carrier films (i.e., the front side and back side films) attached to opposite sides of the wires. The films are typically attached along the wire ends. The films are made from electrically insulating materials and at least the front side film is substantially transparent. The front side film is used to attach the wires to a photovoltaic surface of one cell, while the back side film is used for attachment to a substrate surface of another cell. These attachments electrically interconnect the two cells in series. In certain embodiments, one or both carrier films extend beyond two end wires and form insulated portions that allow much closer arrangements of the cells in a module.