Flexible PV Cell With Segmented Wafer Craters
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Solution Overview
Problem
Current silicon solar modules are rigid and heavy, limiting their application in weight and shape-constrained environments, and existing flexible PV panels are either expensive to produce or lack durability and sufficient flexibility.
Innovation Solution
A flexible and mechanically resilient Photovoltaic (PV) cell is developed using a single semiconductor wafer segmented with non-transcending craters that penetrate from the dark-side to the sunny-side, embedded with conducting wires in an adhesive transparent flexible plastic foil, allowing for enhanced mechanical resilience and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional silicon solar modules are used, then high photovoltaic efficiency is achieved, but the modules are rigid and heavy, limiting applications in weight and shape-constrained environments
Solution Approach 1:
The semiconductor wafer is segmented into multiple sub-regions by non-transcending craters that penetrate from the dark-side surface toward but do not reach the sunny-side surface. This segmentation creates a flexible structure that can bend and conform to various shapes while maintaining structural integrity and photovoltaic functionality.
Solution Approach 2:
The patent employs thin semiconductor wafers with craters that create a flexible, bendable structure. The wafer thickness and crater design enable the PV module to be lightweight and adaptable to curved or irregular surfaces, eliminating the rigidity of traditional silicon modules.
2Adaptability or versatility
If existing flexible PV panels are produced, then weight and shape constraints are addressed, but they are expensive to produce or lack durability and sufficient flexibility
Solution Approach 1:
The crater-based segmentation approach uses a single semiconductor wafer that is divided into sub-regions without requiring multiple separate components or complex assembly processes. This segmentation is achieved through controlled crater formation that penetrates partially through the wafer, creating flexibility while maintaining ease of manufacturing.
Solution Approach 2:
The patent modifies physical parameters of the semiconductor wafer, including thickness and crater depth (non-transcending), to achieve the desired balance between flexibility and durability. These parameter changes enable the wafer to be flexible enough for curved surfaces while remaining durable and cost-effective to produce.
3Strength
If a single semiconductor wafer is used with non-transcending craters, then mechanical resilience and shock absorption are enhanced, but the structural integrity must be maintained
Solution Approach 1:
The non-transcending craters act as pre-formed cushioning structures within the semiconductor wafer. These craters create void spaces that absorb mechanical stress and shock before it can propagate through the entire wafer, enhancing mechanical resilience while the craters do not penetrate completely, thus maintaining structural integrity.
Solution Approach 2:
The semiconductor wafer incorporates a porous structure through the non-transcending craters, creating a network of voids that provide mechanical resilience and shock absorption. The porous structure allows the wafer to flex and absorb impacts while maintaining overall structural stability through the interconnected crater network.
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 provides a cost-effective, durable, and flexible PV cell that can withstand mechanical stress, enabling applications in challenging environments and reducing transportation and installation costs.
Implementation Method 1
The craters segment the wafer into miniature sub-regions, and provide mechanical resilience and mechanical shock absorption
Implementation Method 2
The photovoltaic (PV) effect is the creation of voltage and electric current in a material upon exposure to light
Data Source
AI summary
A flexible and mechanically-resilient Photovoltaic (PV) cell is formed of a single semiconductor wafer. It includes non-transcending craters or bling gaps, that penetrate upwardly from a dark-side surface towards a sunny-side surface but do not reach the sunny-side surface. The craters segment the wafer into miniature sub-regions, and provide mechanical resilience and mechanical shock absorption. A set of conducting wires are located on each side of the PV cell; one set collects the negative electric charge, and the other set collects the positive electric charge. The conducting wires are embedded in an adhesive transparent flexible plastic foil. Optionally, a bi-facial PV cell is similarly provided, as well as methods and systems for producing such PV cells.