Photovoltaic Module Manufacturing via Insulating Strip Interconnects
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Solution Overview
Problem
The manufacturing of organic photovoltaic modules with electrically connected cells is complex due to the need for precise lateral displacement, which hinders the efficiency of continuous roll-to-roll methods and limits the ability to achieve higher DC voltages.
Innovation Solution
A method involving the use of spaced-apart electrode strips and insulating strips on a substrate, with a functional stack of photoactive semiconductor material, allows for precise electrical connections between cells while maintaining the advantages of continuous manufacturing processes, enabling the series connection of any number of cells to achieve desired output voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lateral displacement is applied to electrically connect photovoltaic cells, then electrical connection between cells is achieved, but manufacturing complexity increases due to precision requirements
Solution Approach 1:
The substrate is divided into multiple distinct zones: active areas for photovoltaic cell formation and connecting areas for electrical connections. Insulating strips separate these zones, allowing independent processing and simplifying the overall manufacturing process while ensuring reliable electrical connections between cells.
Solution Approach 2:
Insulating strips serve as intermediary elements that both electrically isolate and mechanically position the photovoltaic cells relative to each other. These strips create dedicated connecting areas that facilitate electrical connection without requiring complex lateral displacement operations.
2Reliability
If precise lateral displacement is required for electrical connection, then cell connection reliability improves, but manufacturing efficiency decreases
Solution Approach 1:
The insulating strips are deposited beforehand to pre-establish the spatial arrangement and electrical isolation scheme. This preliminary action defines connecting areas in advance, eliminating the need for complex real-time alignment operations and enabling continuous high-speed manufacturing while ensuring connection reliability.
Solution Approach 2:
The problem of lateral displacement alignment is resolved by transitioning to a vertical dimension approach. Insulating strips are deposited in the cross-web direction to create horizontal separation and defining connecting areas, allowing continuous forward motion in the down-web direction without complex lateral positioning operations.
3Power
If series connection of multiple cells is implemented, then output voltage increases, but manufacturing complexity increases
Solution Approach 1:
The insulating strips perform multiple functions simultaneously: they electrically isolate adjacent cells, mechanically position cells with precise spacing, and create dedicated connecting areas for series connections. This multi-functionality enables series connection of multiple cells to achieve higher voltages without proportionally increasing manufacturing complexity.
Solution Approach 2:
The insulating strips automatically define the connecting areas and establish the electrical connection scheme through their deposition pattern. The manufacturing process itself creates the connection architecture without requiring additional complex steps, allowing scalable series connection of cells.
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 method simplifies the electrical connection of photovoltaic cells in series, allowing for customizable output voltages and maintaining the efficiency of continuous manufacturing processes, while improving voltage generation and reducing power loss.
Implementation Method 1
A photovoltaic cell is an electronic component which when exposed to light (photons), produces electricity by means of the photovoltaic effect
Data Source
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AI summary
The invention concerns a method of manufacturing a photovoltaic module comprising at least two electrically connected photovoltaic cells, each photovoltaic cell (4i) being multi-layered structure disposed on a substrate (6) having down-web direction (X) and a cross-web direction (Y). The method comprises providing a plurality of spaced-apart first electrode strips (8i) over the substrate (6), each first electrode strip extending along the cross-web direction (Y), and providing, over the first electrode strips layer, at least one insulating strip (14a, 14b) of an insulator material extending along the down-web direction (X), each insulating strip defining a connecting area and an active area. A functional stack (20) comprising a full web coated layer of photoactive semiconductor material is formed over the first layer and within the active area. A plurality of spaced-apart second electrode strips (28i) are provided within the active area, each second electrode strip extending along the cross-web direction (Y), so as to form photovoltaic cells and a photovoltaic module is formed by electrically connecting at least two adjacent photovoltaic cells, by extending over the insulating strips (14a, 14b) electrical connection patterns to electrically connect, within the connecting area(s), the second electrode strip of an photovoltaic cell to the first electrode strip of an adjacent photovoltaic cell.