PV Cell Interconnection Layout for Shade-Tolerant Roof Fill
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Solution Overview
Problem
Existing photovoltaic circuit designs face inefficiencies due to the use of bus ribbons that occupy space, increase complexity, and reduce power density, while existing bypass diodes cause significant energy yield loss from shading, and there is a need for improved shade tolerance and roof fill capabilities.
Innovation Solution
The integration of conductive interconnection components, such as laser-welded aluminum foil, that extend between photovoltaic cells to connect substrings and facilitate easier integration of bypass diodes, allowing for enhanced shade tolerance and increased photovoltaic cell coverage without additional power electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If bus ribbons are used to connect photovoltaic substrings, then electrical connection is achieved, but space is occupied and power density is reduced
Solution Approach 1:
The patent combines the electrical interconnection function and the bypass diode mounting function into a single integrated component. The conductive interconnection component serves dual purposes: connecting photovoltaic substrings electrically and providing a mounting structure for bypass diodes, thereby eliminating the need for separate bus ribbons and reducing inactive space.
Solution Approach 2:
The conductive interconnection component is designed to perform multiple functions simultaneously: it acts as an electrical conductor for connecting substrings, provides structural support for mounting bypass diodes, and serves as part of the overall module framework. This multi-functionality reduces the number of separate components needed and increases power density.
2Reliability
If traditional bypass diodes are used, then shading protection is provided, but significant energy yield loss occurs
Solution Approach 1:
The bypass diodes are pre-integrated into the conductive interconnection components during manufacturing, positioned optimally before module assembly. This preliminary integration ensures that the bypass paths are already established and optimized, allowing for faster response to shading conditions and minimizing energy yield loss when shading occurs.
3Reliability
If complex ribbon circuits are used, then electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent merges the ribbon circuit formation with the conductive interconnection components. The interconnection components themselves form the electrical pathways, eliminating the need for separate ribbon circuits. This integration simplifies the overall device structure and reduces manufacturing complexity.
4Area of stationary object
If more photovoltaic cells are installed to increase coverage, then roof fill capability is improved, but complexity and space requirements increase
Solution Approach 1:
The conductive interconnection components serve multiple functions including electrical connection, structural support, and bypass diode mounting. This multi-functionality allows for increased photovoltaic cell coverage without proportionally increasing complexity, as the same components handle multiple tasks rather than requiring additional specialized components for each function.
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 solution enhances power output, reduces energy yield loss from shading, and increases roof fill capabilities by simplifying ribbon circuit formation and reducing inactive space, while maintaining efficient operation under varying shading conditions.
Implementation Method 1
The conductive material of the at least one cell interconnection component may include laser-welded aluminum foil
Implementation Method 2
The conductive material of the at least one cell interconnection component may include laser-welded aluminum foil
Implementation Method 3
Photovoltaic modules are utilized on roofing of structures to absorb sunlight to generate energy that may be converted for use on an electrical grid
Data Source
AI summary
An integrated cell and circuit interconnection for photovoltaic devices is disclosed. Interconnection componentry includes conductive material utilized to connect a negative terminal of a photovoltaic cell of a substring of a photovoltaic device to a positive terminal of a photovoltaic cell of another substring of the photovoltaic device to electrically connect the cells together. Certain interconnection componentry include extension portions that extend beyond the edge of the photovoltaic cells to which the interconnection componentry are connected. The extension portions are configured to connect to an electrical circuit of the photovoltaic device and connect the substrings to which the extension portions are attached to other substrings of the photovoltaic device. The interconnection componentry and extension portions facilitate bypass diode integration into the electrical circuit, while optimizing shade tolerance of the photovoltaic device and increasing roof fill with regard to a roof on which the photovoltaic device is secured.