Photovoltaic Cell Array With Segmented Modules And Flexible Connections
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Solution Overview
Problem
Conventional photovoltaic panels face limited lifespan and efficiency due to thermal deformations, fatigue from repeated deformations, and manufacturing issues, leading to operational problems and rejection.
Innovation Solution
The design features cells with lateral notches for ribbon insertion, allowing adjacent cells to abut, and connection pads with reduced dimensions to minimize stress and deformation, along with copper ribbons and specific collector structures to enhance flexibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photovoltaic panels are subjected to thermal deformations and repeated deformations, then the panel undergoes fatigue and operational problems, but the lifespan and reliability decrease
Solution Approach 1:
The photovoltaic panel is divided into modular assemblies, each comprising a limited number of cells (e.g., 2-4 cells) connected in series. These modules are separated by spacing elements, creating a segmented structure that allows independent movement and deformation of each module without affecting the entire panel, thereby reducing stress concentration and fatigue.
Solution Approach 2:
The patent employs flexible connection ribbons and elastic spacing elements that can deform elastically under thermal stress and mechanical loads. These flexible components accommodate panel deformation without causing fatigue failure, maintaining structural integrity over time.
2Adaptability or versatility
If cells are arranged with larger spacing to accommodate thermal deformation, then flexibility is improved, but the power output per unit area decreases
Solution Approach 1:
By segmenting the panel into small modules with limited cells per module, the patent minimizes the spacing required between modules while still providing adequate room for thermal deformation. This segmentation allows the panel to maintain high cell density and power output while accommodating thermal expansion through the flexible connections between modules.
Solution Approach 2:
The patent uses dynamic, flexible spacing elements and connection ribbons that can adapt their configuration based on thermal conditions. During normal operation, the flexible components maintain minimal spacing to maximize power output, while automatically accommodating thermal deformation when temperature changes occur.
3Reliability
If connection strips are made rigid to ensure electrical connection, then electrical conductivity is improved, but the panel cannot withstand deformations
Solution Approach 1:
The patent employs flexible connection ribbons with sufficient electrical conductivity that can bend and deform elastically while maintaining electrical contact. These flexible ribbons accommodate panel deformation without compromising electrical connection reliability, unlike rigid strips that would fracture under stress.
Solution Approach 2:
The connection system uses composite structures combining conductive materials with flexible substrates, creating connection elements that simultaneously provide electrical conductivity and mechanical flexibility to withstand thermal and environmental deformations.
4Ease of manufacture
If manufacturing processes subject assemblies to high temperatures, then assembly is facilitated, but thermal stress causes operational problems and rejection
Solution Approach 1:
By manufacturing smaller modular assemblies rather than large panels, the patent reduces the overall thermal stress experienced during manufacturing processes. The segmented structure allows heat to be more evenly distributed and managed, reducing thermal gradients and stress concentration that lead to operational problems.
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 configuration enables photovoltaic devices to withstand temperature variations and deformations, extending lifespan, improving power output per unit area, and reducing manufacturing inefficiencies.
Implementation Method 1
When the cells are exposed to sunlight, the current produced by each cell is collected on the rear face by the collector structure 10
Implementation Method 2
the elements constituting the panel expand and contract thermally to the rhythm of the days and cloudy passages
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
The invention relates to a photovoltaic device comprising juxtaposed cells (32) that are connected in series by conductive strips (42), each strip being welded both to a first bonding pad (36) on the front side of a first cell, and to a second bonding pad (40) on the rear side of a second cell that is adjacent to the first cell, said second bonding pad being positioned fully within the half of the second cell that is furthest away from the first cell.