Photovoltaic Cell Segmentation for Voltage Increase
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Solution Overview
Problem
Existing methods for increasing the voltage of photovoltaic panels are either complex, require significant modifications to industrial equipment, or complicate the sorting and production of photovoltaic cells, leading to increased costs and reduced production efficiency.
Innovation Solution
A method involving the electrical connection of photovoltaic cells in series, followed by laser-cutting into sub-cells along specific trenches to form sub-rows, which are then connected in series, allowing for increased voltage without modifying existing production lines or impacting cell sorting, using a LASER treatment to embrittle the cells and facilitate mechanical cleavage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the voltage of photovoltaic cells is increased to achieve higher panel voltage, then the panel voltage increases, but complex insulation is required
Solution Approach 1:
The photovoltaic cell is divided into multiple sub-cells by cutting along predetermined lines, creating isolated regions that can be independently managed electrically. This segmentation allows voltage increase through series connection of sub-cells without requiring complex insulation across the entire cell structure.
Solution Approach 2:
Dielectric material is introduced as an intermediary substance between adjacent sub-cells during the cutting process. This dielectric layer provides electrical insulation between the high-voltage sub-cells, enabling high voltage operation without complex insulation systems.
2Power
If the number of photovoltaic cells is increased to achieve higher panel voltage, then the panel voltage increases, but the cell sorting process is complicated and manufacturing costs increase
Solution Approach 1:
Instead of increasing the number of separate cells, the invention segments each cell into sub-cells that are then electrically connected in series. This approach achieves the same voltage increase while maintaining the original cell count, thereby simplifying the sorting process and preserving manufacturing efficiency.
Solution Approach 2:
Multiple sub-cells within each photovoltaic cell are electrically connected in series to achieve the voltage increase. This merging of sub-cells into a single functional unit allows the system to achieve high voltage without increasing the number of discrete cells that would need to be sorted and assembled.
3Power
If the size of photovoltaic cells is reduced to increase the number of cells per panel, then the panel voltage increases, but production equipment must be adapted and production rates may slow
Solution Approach 1:
The invention segments existing standard-sized cells into sub-cells through cutting, rather than manufacturing smaller cells from scratch. This approach allows the use of existing production equipment designed for standard cell sizes, avoiding the need for equipment adaptation while still achieving the desired voltage increase.
Solution Approach 2:
The cutting lines and dielectric material application are performed as preliminary actions during the cell manufacturing process, before the cells are assembled into panels. This preliminary segmentation allows standard production equipment to handle the cells without modification, as the voltage-increasing feature is already built into each cell structure.
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 method effectively increases the voltage of photovoltaic panels without altering standard production processes, reduces production costs, and allows for adjustable transparency by spacing sub-rows, enhancing efficiency and adaptability in applications like building and agricultural settings.
Implementation Method 1
step a1) being a step of embrittlement along the cut lines of each photovoltaic cell, step a1) comprising the formation of trenches along the cutting lines in the photovoltaic cells, advantageously, the formation of the trenches being carried out by a LASER treatment
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to a method for manufacturing a photovoltaic element comprising: a) a step of connecting in series photovoltaic cells (210), arranged in a row (200), the connection between two photovoltaic cells (210) being ensured by parallel conductive tracks; b) a step of cutting, along lines (250), each photovoltaic cell (210) into photovoltaic sub-cells, so as to form a plurality of sub-rows, said sub-rows being parallel to each other, the cutting also being carried out so that the sub-cells are connected in series; c) an electrical connection step of two sub-rows of sub-cells, such that all sub-cells of the two sub-rows are connected in series, the process further includes a step a1), preceding step b), said step a1) being a weakening step along the lines (250) of the photovoltaic cells (210).