Photovoltaic Module Rear Interconnector Layout
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Solution Overview
Problem
Conventional photovoltaic modules have reduced module efficiency due to the area occupied by interconnectors, which also lead to increased resistance loss and the generation of air bubbles during the laminating process, causing stress on solar cells and reducing manufacturing yield.
Innovation Solution
The photovoltaic module design features interconnectors arranged on the rear surface side of the solar cells, using a metal foil coated with a laminated film for self-adhesiveness, with wide tab connectors and alternating polarity of adjacent units to minimize overlap and resistance, thereby reducing the area occupied by interconnectors and dispersing pressure evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If interconnectors have large cross-sectional area to reduce resistance loss, then resistance loss is reduced, but area of photovoltaic submodule is increased, reducing module efficiency
Solution Approach 1:
The interconnectors are arranged on the rear surface side of the solar cells instead of the front surface, utilizing the unused rear space. This dimensional relocation allows the interconnectors to have sufficient cross-sectional area for low resistance without occupying the light-receiving area, thus resolving the contradiction between reducing resistance loss and maintaining module efficiency.
2Loss of energy
If interconnectors have increased thickness to reduce resistance loss, then resistance loss is reduced, but air bubbles are generated during lamination, reducing manufacturing yield
Solution Approach 1:
By relocating interconnectors to the rear surface side, the patent enables the use of thicker interconnectors for reduced resistance without causing air bubble formation during lamination, as the thicker interconnectors are positioned where they will not interfere with the lamination process of the front surface components.
Solution Approach 2:
The interconnectors are extracted from the front surface assembly and placed on the rear surface, separating them from the lamination process. This extraction eliminates the harmful effect of air bubble generation while preserving the beneficial effect of reduced resistance loss through increased thickness.
3Reliability
If interconnectors are arranged at periphery to connect units, then electrical connection between units is achieved, but area occupied by interconnectors is increased, reducing power generating region
Solution Approach 1:
The patent relocates interconnectors from the front surface periphery to the rear surface side, utilizing the unused rear space for electrical connections. This allows the front surface to be fully utilized for power generation while the rear interconnectors maintain electrical connectivity between units without occupying light-receiving 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 design enhances module efficiency, reduces the area occupied by interconnectors, prevents air bubble formation, and minimizes stress on solar cells, leading to improved manufacturing yields and reduced weight and size of the module.
Implementation Method 1
The solar cells are sealed with a light-transmitting sealant such as EVA (Ethylene Vinyl Acetate) having excellent weather resistance and moisture resistance between a light-transmitting front surface member such as glass and light-transmitting plastic and a rear surface member
Implementation Method 2
solar cells that can convert light from the sun, which is a clean inexhaustible energy source, directly into electricity
Data Source
AI summary
It is an object of the present invention to provide a photovoltaic module capable of reducing an area occupied by interconnectors. The photovoltaic module of the present invention comprises light-transmitting substrate, strings including a plurality of solar cells interconnected through tab connector, and rear surface member. A plurality of the strings is electrically connected through interconnectors and arranged on a rear surface side so as not to overlap each other. The photovoltaic module is sealed with a sealant between the light-transmitting substrate and the rear surface member.