PV Top Module Grid Layout for Tandem Voltage Matching
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Solution Overview
Problem
Si-based PV modules have limitations in efficiency due to the challenges of integrating high-efficiency thin film absorber materials with high band gaps into existing manufacturing infrastructure, leading to difficulties in voltage matching and increased parasitic resistive power loss when stacked with Si-based modules.
Innovation Solution
A PV top module is manufactured using monolithically interconnected thin film PV sub-cells made from perovskite or CIGS materials, with metal grid lines arranged on top and bottom contact layers to improve conductivity and allow wider cells, enabling the creation of a tandem PV module with an Si-based PV bottom module, connected in parallel to achieve higher efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thin film based PV sub-cells with high efficiency absorber materials are used to significantly increase efficiency, then efficiency is improved, but parasitic resistive power loss increases and voltage matching becomes difficult
Solution Approach 1:
The PV module is divided into two distinct sub-modules: a thin film based PV top sub-module with high efficiency absorber materials and a Si-based PV bottom sub-module. This segmentation allows each sub-module to be optimized independently, with the thin film sub-module capturing high-energy photons and the Si-based sub-module capturing lower-energy photons, thereby increasing overall efficiency while managing parasitic losses through separate optimization paths
Solution Approach 2:
The patent transitions from a single-junction planar structure to a multi-junction stacked configuration, adding the vertical dimension of multiple absorption layers. This dimensional change enables the system to utilize different portions of the solar spectrum at different depths, with the thin film layer absorbing high-energy photons first and the Si-based layer absorbing remaining photons, thus increasing efficiency without proportionally increasing parasitic losses
2Ease of manufacture
If thin film module is connected in parallel with Si module, then integration into existing infrastructure is simplified, but voltage matching becomes difficult due to larger number of thin film sub-cells required
Solution Approach 1:
The patent adjusts key parameters including the number of thin film sub-cells, their individual areas, and connection configurations to match the voltage output of the Si-based sub-module. By changing these parameters, the system achieves voltage compatibility for parallel connection while maintaining the simplicity of integration into existing infrastructure
3Productivity
If monolithic interconnection is used with high efficiency absorber materials, then efficiency is improved, but narrow thin film based PV sub-cells are required increasing manufacturing difficulty
Solution Approach 1:
The patent segments the PV module into separate thin film and Si-based sub-modules that can be manufactured independently using established processes. This segmentation allows the thin film sub-cells to be manufactured at standard widths without requiring complex narrow cell fabrication, while still achieving high efficiency through the stacked configuration and selective photon absorption
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 configuration significantly increases the efficiency of Si-based PV modules by up to 50% while maintaining similar output voltage, reducing parasitic resistive power loss and enabling cost-effective integration with existing manufacturing infrastructure.
Implementation Method 1
PV modules commonly comprise Si-based PV sub-cells as solar cells
Implementation Method 2
a thin film absorber material with high efficiency at a suitable band gap is needed
Data Source
AI summary
In accordance with one or more embodiments herein, a method of manufacturing a photovoltaic (PV) top module, to be used together with a PV bottom module, e.g an SI-based PV bottom module, is provided. The method may include monolithically interconnecting a plurality of thin film based PV sub-cells, manufactured using a perovskite material and/or a CIGS material as solar absorbing material, in series on a substrate in order to create a PV top module including at least one first PV top sub-module, and arranging metal grid lines on top and bottom contact layers of the PV top module. The metal grid lines may be arranged either above or below the top and bottom contact layers of the PV top module.