PV Module Assembly With Power Optimizers for Partial Shade
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Solution Overview
Problem
Existing photovoltaic modules are sensitive to partial shade conditions, leading to hot-spot heating and power loss, and the incorporation of bypass diodes to mitigate this issue is costly and complex.
Innovation Solution
A photovoltaic module design featuring parallel-connected sub-strings of series-connected back-contact solar cells with integrated power optimizer circuits, eliminating the need for bypass diodes and optimizing power output under shade conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bypass diodes are used to protect against hot-spot heating in partial shade conditions, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes bypass diodes from the system entirely and replaces them with a back-contact cell design where the metallization pattern on the rear surface inherently provides current collection paths that prevent hot-spot formation. The back-contact structure extracts the protective function without requiring separate diode components.
Solution Approach 2:
The back-contact metallization pattern serves multiple functions simultaneously: it collects current from the solar cells and provides hot-spot protection through its specific geometric configuration. This multi-functional design eliminates the need for separate bypass diodes while maintaining both current collection efficiency and protection against partial shading effects.
2Reliability
If bypass diodes are integrated into photovoltaic modules to improve shadow performance, then performance under partial shade is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the shadow protection function from separate bypass diode components and integrates it directly into the back-contact cell structure. This eliminates the need to purchase, store, and install bypass diodes, thereby reducing manufacturing costs while maintaining shadow performance.
Solution Approach 2:
The protective function against partial shading is merged with the current collection function in the back-contact metallization pattern. By combining these functions into a single integrated structure, the patent reduces component count and manufacturing complexity, leading to lower production costs.
3Productivity
If complex connection patterns are used to optimize power output in partial shade conditions, then power output is improved, but assembly difficulty increases
Solution Approach 1:
The back-contact metallization pattern is designed with locally optimized geometry that automatically adapts to partial shading conditions. Different regions of the back-contact pattern have specific configurations that optimize current collection from locally illuminated cell regions, eliminating the need for complex global reconfiguration during assembly.
Solution Approach 2:
The back-contact cell structure inherently optimizes its own performance under partial shade conditions through its geometric design. The metallization pattern automatically provides appropriate current collection paths based on the local illumination conditions without requiring external control or complex assembly procedures.
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 design provides improved shadow performance and hot-spot prevention while reducing assembly complexity and costs, maintaining optimal power output even under partial shade.
Implementation Method 1
a photovoltaic module comprising a positive terminal, a negative terminal, at least two sub-modules, wherein each of the at least two sub-modules comprises x parallel-connected sub-strings, wherein each of the x parallel-connected sub-strings comprises y series-connected sub-cells
Data Source
AI summary
A photovoltaic (PV) module (1) comprising a positive terminal (5), a negative terminal (6), and at least two sub-modules. Each of the at least two sub-modules (10a-c) comprises x parallel-connected sub-strings (13), wherein each of the x parallel-connected sub-strings (13) comprises y series-connected sub-cells (16), wherein the y series-connected sub-cells (16) are arranged in an array. The PV module (1) further comprises a back conductive sheet having a first connection pattern arranged for connecting the x parallel-connected sub-strings (13) of each of the at least two sub-modules (10a-c), wherein each of the at least two sub-modules (10a-c) is provided with a power optimizer circuit (21a-c), and the output of the power optimizer circuits (21a-c) are connected in series between the positive terminal (5) and the negative terminal (6).