Photovoltaic Module Interconnection for Denser Cell-String Layout
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Solution Overview
Problem
The high area occupancy rate of current collectors in photovoltaic modules due to their larger cross-sectional area compared to interconnection ribbons leads to increased spacing between cell strings, affecting the appearance and efficiency of the module.
Innovation Solution
The introduction of intermediate interconnection structures with overlapping projections on cell edges, allowing electrical connection without occupying the space between adjacent cell strings, reducing the need for additional spacing and minimizing the area occupied by these structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current collectors are used to connect adjacent cell strings, then electrical connection between cell strings is achieved, but the area occupancy rate increases and spacing between cell strings must be increased
Solution Approach 1:
The intermediate interconnection structure extends in the thickness direction (third direction) of the cell, allowing the orthographic projection on the reference plane to overlap with the cell projection. This vertical dimensionality change enables electrical connection without occupying horizontal space between cell strings, resolving the contradiction between connection reliability and area occupancy.
Solution Approach 2:
The intermediate interconnection structure is positioned such that its projection overlaps with the cell projection, effectively nesting the interconnection function within the cell's spatial footprint. This allows the interconnection structure to utilize the vertical space above/below the cell rather than requiring additional horizontal spacing.
2Power
If current collectors with larger cross-sectional area are used, then current transmission capacity is improved, but spacing between cell strings must be increased
Solution Approach 1:
The intermediate interconnection structure utilizes the thickness direction (third direction) to accommodate its cross-sectional area, allowing it to extend vertically rather than horizontally. This enables sufficient current transmission capacity without increasing the horizontal spacing between cell strings in the first direction.
3Ease of manufacture
If spacing between cell strings is increased to accommodate current collectors, then current collector placement is facilitated, but arrangement density of cell strings decreases
Solution Approach 1:
By extending the intermediate interconnection structure in the thickness direction, the design eliminates the need for horizontal spacing between cell strings. The structure can be manufactured and placed using standard welding processes while achieving higher arrangement density due to the reduced spacing requirements.
4Area of stationary object
If intermediate interconnection structures with overlapping projections are used, then spacing between cell strings is reduced, but structural complexity increases
Solution Approach 1:
The intermediate interconnection structure is divided into multiple portions (first portion, second portion, lead-out structure) that can be separately manufactured and then assembled. This segmentation simplifies the manufacturing process despite the complex three-dimensional configuration, as each portion can be produced using standard processes and then joined together.
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 design enhances the arrangement density of cell strings, improves the aesthetic appearance, and increases the efficiency of the photovoltaic module by reducing material costs and optimizing the layout.
Implementation Method 1
a respective solder ribbon structure of the solder ribbon structures is disposed on a corresponding cell of the at least two cells of a corresponding cell string of the at least two cell strings, and the respective solder ribbon structure is in electrical contact with a corresponding electrode of the electrodes of the corresponding cell
Implementation Method 2
a respective intermediate interconnection structure of the intermediate interconnection structures is electrically connected with a respective pair of adjacent cell strings of the at least two cell strings
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Embodiments of the present disclosure relate to the technical field of photovoltaics, and provide a photovoltaic module and a method for manufacturing the same. The photovoltaic module includes: at least two cell strings spaced apart from one another in a first direction; solder ribbon structures, where a respective solder ribbon structure of the solder ribbon structures is disposed on a corresponding cell of the at least two cells of a corresponding cell string of the at least two cell strings; and intermediate interconnection structures, where a respective intermediate interconnection structure of the intermediate interconnection structures is electrically connected with a respective pair of adjacent cell strings of the at least two cell strings.