Photovoltaic Cell Sheet with Sawtooth Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing tile-stacking photovoltaic module technology faces challenges due to overlapping contact between cell sheets, leading to reduced effective area utilization and increased requirements for accuracy in printing gratings and module packing, which are difficult to achieve and costly.
Innovation Solution
A photovoltaic cell sheet design featuring a cell sheet body with sawtooth spacing at one end, main gates at both sides, and sub-gates connected to the main gates, manufactured through specific printing and cutting processes, reduces mutual occlusion area and lowers accuracy requirements for printing and module packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the overlap width between cell sheets is reduced to reduce mutual occlusion, then the effective area utilization is improved, but the requirements for accuracy in printing gratings and module packing equipment significantly increase
Solution Approach 1:
The cell sheet is divided into multiple segments with different functions: the first end has sawtooth-shaped segments for connection, while the second end has straight segments. This segmentation allows the cell sheet to be connected through overlapping while maintaining electrical connectivity and reducing mutual occlusion, as the segments are designed to interlock rather than requiring precise alignment of entire sheets.
Solution Approach 2:
The cell sheet employs asymmetric design where the first end features sawtooth-shaped cutting lines and the second end features straight cutting lines. This asymmetric configuration enables the cell sheets to connect in a specific orientation, reducing the need for high precision in printing and packing while maintaining effective area utilization through optimized overlap geometry.
2Area of stationary object
If the overlap width between cell sheets is reduced to reduce mutual occlusion, then the effective area utilization is improved, but the manufacturing cost and complexity increase due to higher accuracy requirements
Solution Approach 1:
By segmenting the cell sheet into distinct functional zones (sawtooth end and straight end), the design simplifies the manufacturing process. The segmented structure allows for standard printing and cutting operations without requiring high-precision equipment, thereby reducing manufacturing complexity and cost while maintaining effective area utilization.
Solution Approach 2:
The cell sheet design accepts that some overlap and mutual occlusion are inevitable in the tile-stacking configuration, rather than attempting to eliminate them through high-precision manufacturing. This approach prioritizes cost-effective, straightforward manufacturing processes over perfect alignment, accepting minor area loss in exchange for significantly reduced manufacturing complexity.
3Device complexity
If cell sheets are connected through overlapping contact in tile-stacking module, then the module structure is simplified, but the cell sheets are shielded from each other leading to reduced effective area
Solution Approach 1:
The asymmetric design with sawtooth and straight segments at different ends enables the cell sheets to connect in a way that minimizes shielding. The sawtooth segments interlock with adjacent sheets while the straight segments maintain electrical connectivity, allowing the module structure to remain simple while reducing the shielding effect on the effective area.
Solution Approach 2:
The design utilizes the length dimension of the cell sheet by placing different cutting line configurations at different ends. This dimensional approach allows the cell sheet to connect through overlap in the width direction while maintaining effective area in the length direction, as the sawtooth and straight segments are positioned to minimize mutual occlusion along the light path.
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 solution reduces the mutual occlusion area between cell sheets, increases accuracy and fault tolerance in printing and module packing, and decreases manufacturing costs and complexity, resulting in a larger effective area for the photovoltaic cell sheet.
Implementation Method 1
Photovoltaic cell sheet and method of manufacturing the same
Data Source
AI summary
The photovoltaic cell sheet includes: a cell sheet body having a first end and a second end opposite to each other in a width direction of the cell sheet body, wherein the first end of the cell sheet body is provided with a plurality of sawtooth spacing along a length direction of the cell sheet body; a first main gate arranged at one side of front and back sides of the plurality of sawtooth and serving as a first electrode; and a second main gate arranged at another side of the front and back sides of the cell sheet body and serving as a second electrode, wherein the second main gate is adjacent to the second end of the cell sheet body.