Thin-Film PV Module Edge-Integrated Electronics
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Solution Overview
Problem
Thin-film photovoltaic modules with monolithically integrated cells on non-conductive substrates face challenges in reducing shading losses and electrical resistance when integrating electronic devices like bypass diodes and switches, leading to ineffective operation and high resistive losses.
Innovation Solution
The integration of electronic devices such as bypass diodes, switches, or DC/DC converters at the lateral edge of the module, connected via conductive wires that overlay the front side electrodes of specific cells, reducing electrical resistance and minimizing shading effects by using wires with lower resistance than the electrodes and positioning them to avoid short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bypass diodes are positioned at the lateral edge of the module and connected to front side contacts, then device integration is achieved, but electrical resistance increases due to long current paths through high-resistance transparent electrodes
Solution Approach 1:
The patent introduces a conductive wire as an intermediary element to connect the bypass diode to the front side contact. This wire serves as a mediator that provides a low-resistance current path, bypassing the high-resistance transparent electrode material. The wire is positioned to overlay the transparent electrode, creating a parallel conduction path that significantly reduces the total resistance of the bypass circuit.
Solution Approach 2:
The solution combines different conductive materials to create a composite current path. The transparent conductive oxide (TCO) electrode with relatively high resistance is complemented by a low-resistance metal wire, forming a hybrid conduction system. This composite approach leverages the advantages of both materials: the TCO provides optical transparency and basic conductivity, while the metal wire provides low-resistance shunt paths.
2Adaptability or versatility
If electronic devices are integrated at the module edge, then device functionality is added, but resistive losses increase due to current flow through high-resistance transparent electrodes
Solution Approach 1:
The conductive wire acts as an intermediary that creates a preferential low-resistance path for current flow. By placing the wire in overlay with the transparent electrode, the system provides a mediator through which current can flow with minimal resistance, thereby reducing I²R losses in the transparent electrode material while still enabling electronic device functionality.
Solution Approach 2:
The patent changes the electrical resistance parameter of the current path by introducing a low-resistance wire. This parameter change transforms the high-resistance path through the transparent electrode into a low-resistance hybrid path, significantly reducing resistive energy losses while maintaining the necessary electrical connections for electronic devices.
3Reliability
If conductive wires are used to connect electronic devices, then electrical resistance is reduced, but shading losses increase due to wire coverage on active cell areas
Solution Approach 1:
The patent applies local quality by positioning the conductive wire specifically where it is most needed - overlaying the transparent electrode in regions where current collection is required. The wire is strategically placed to provide local low-resistance paths without unnecessarily covering large active cell areas. This localized approach minimizes shading losses while maintaining current path efficiency in critical regions.
Solution Approach 2:
The solution uses partial action by implementing wire connections only where necessary to achieve the desired electrical resistance reduction, rather than covering the entire module. The wire overlay is applied selectively to specific regions where electronic devices are integrated, providing sufficient current path improvement without excessive shading of the photovoltaic active area.
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 approach significantly reduces resistive losses and enhances the operation of integrated electronic devices, improving the module's performance, reliability, and energy output by ensuring efficient current paths and minimal shading impacts.
Implementation Method 1
The first electrically conductive wire is oriented substantially parallel with the oblong direction of the front side electrode of the first thin-film photovoltaic cell such that the first electrically conductive wire overlaps only with the front side electrode of the first thin-film photovoltaic cell... establishing a first electrical connection between the first device electrode and the front side electrode of the first thin-film photovoltaic cell by means of the first electrically conductive wire
Implementation Method 2
a plurality of thin-film photovoltaic cells, each of the thin-film photovoltaic cells having a cell length and a cell width... each of the plurality of thin-film photovoltaic cells has an optically transparent front side electrode at a front side
Data Source
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AI summary
The disclosure provides a thin-film photovoltaic module comprising a plurality of series-connected thin-film photovoltaic cells on an electrically insulating substrate and comprising at least one electronic device integrated with the thin-film photovoltaic module and positioned at a lateral edge of the thin-film photovoltaic module. A first device electrode of the at least one electronic device is electrically connected to a transparent front side electrode of a first thin-film photovoltaic cell by means of a first electrically conductive wire and a second device electrode of the at least one electronic device is electrically connected to a transparent front side electrode of a second thin-film photovoltaic cell by means of a second electrically conductive wire. The disclosure further provides methods for manufacturing such thin-film photovoltaic module with integrated electronic devices.