Overlapping Photoelectric Module Layout for Short-Circuit Isolation
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Solution Overview
Problem
Existing photoelectric conversion modules face issues with short circuits between adjacent photoelectric conversion elements due to insulating covers protruding from the substrate, contaminating manufacturing apparatuses and causing potential electrical connections.
Innovation Solution
A photoelectric conversion module design where adjacent elements are partially overlapping with a conductive substrate connection, separated by an insulating material, preventing direct electrical contact and using flexible substrates to minimize warpage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all side surfaces of the photoelectric conversion element are covered with an insulating cover over the entire circumference, then short circuits between adjacent photoelectric conversion elements are suppressed, but the insulating cover protrudes from the substrate and contaminates the manufacturing apparatus stage
Solution Approach 1:
The insulating cover is divided into two distinct parts: a first insulating cover that covers the side surface of the photoelectric conversion element, and a second insulating cover that covers the end surface. This segmentation allows each cover to be optimized for its specific function - the first cover provides electrical insulation while the second cover prevents protrusion and contamination, thereby resolving the contradiction between short circuit suppression and contamination prevention
Solution Approach 2:
Different insulating covers are applied to different locations of the photoelectric conversion element based on local requirements. The first insulating cover is applied to side surfaces where electrical insulation is needed, while the second insulating cover is applied to the end surface where protrusion prevention is critical. This local differentiation ensures that each area receives the appropriate insulation without causing contamination
2Productivity
If photoelectric conversion elements are arranged side by side with partial overlap, then connection efficiency is improved and module size is reduced, but short circuits may occur between adjacent elements
Solution Approach 1:
The insulating covers are pre-applied to the photoelectric conversion elements before they are arranged and connected in the module. The first insulating cover is applied to the side surfaces and the second insulating cover is applied to the end surfaces in advance, ensuring that electrical insulation is already in place before the elements are positioned close together for partial overlap arrangement, thus preventing short circuits while maintaining connection efficiency
Solution Approach 2:
The insulating covers act as intermediary layers between adjacent photoelectric conversion elements. The first insulating cover on the side surface and the second insulating cover on the end surface create electrical isolation barriers that prevent direct contact between conductive parts of adjacent elements, enabling the elements to be arranged in close proximity for efficient space utilization without causing short circuits
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 design effectively suppresses short circuits while maintaining high photoelectric conversion efficiency and reducing module size, with flexible substrates allowing for efficient assembly and reduced contamination risks.
Implementation Method 1
an insulating material that separates the conductive substrate of the second photoelectric conversion element from the conductive substrate of the first photoelectric conversion element is provided on the conductive substrate of the second photoelectric conversion element
Implementation Method 2
Photoelectric conversion modules that convert light energy into electrical energy
Data Source
AI summary
Provided is a photoelectric conversion module capable of suppressing a short circuit between photoelectric conversion elements adjacent to each other. The photoelectric conversion module (100) comprises a first photoelectric conversion element (10a) including a conductive substrate (20a) and a second photoelectric conversion element (10b) including a conductive substrate (20b). The first photoelectric conversion element and the second photoelectric conversion element are arranged side by side so as to partially overlap each other. A part of the conductive substrate of the second photoelectric conversion element is electrically connected to the first photoelectric conversion element. An insulating material (50b) that separates the conductive substrate of the second photoelectric conversion element from the conductive substrate of the first photoelectric conversion element is provided on the conductive substrate (20b) of the second photoelectric conversion element.