Shingled Photovoltaic Cell Module with Shadowed Bypass Diodes
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Solution Overview
Problem
Current dense array concentrated photovoltaic cell modules face challenges in energy conversion efficiency due to dead space and flux variation, with existing shingle arrangements proving impractical for large-scale systems, leading to low voltage, high mechanical strain, poor heat transfer, and increased costs.
Innovation Solution
A photovoltaic cell assembly with a substrate featuring metallised elements that allow for a shingle arrangement with by-pass diodes positioned in the shadows of cells, providing direct heat and electricity pathways, and a Z-shaped connection for efficient series and parallel connections, minimizing dead space and enhancing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a shingle arrangement of photovoltaic cells is used to increase Active Cell Area Ratio, then energy conversion efficiency is improved, but mechanical strain on cells increases and structural reliability deteriorates
Solution Approach 1:
The photovoltaic cell assembly is segmented into multiple independent strings, each containing series-connected cells. This segmentation allows the high ACAR design to be distributed across multiple smaller units, reducing mechanical strain on individual cells while maintaining overall productivity through parallel string configuration.
Solution Approach 2:
Different regions of the cell assembly have different structural characteristics. The shingled overlap regions provide enhanced mechanical support and reduced strain, while the exposed active surfaces maximize energy conversion. This local differentiation resolves the contradiction between high ACAR and structural reliability.
2Productivity
If cells are closely packed to achieve high ACAR, then energy conversion efficiency is improved, but heat dissipation becomes difficult and temperature increases
Solution Approach 1:
A coolant chamber is introduced as an intermediary thermal management system between the closely packed cells. This mediator enables effective heat dissipation from the high-density cell arrangement, allowing high ACAR to be maintained without excessive temperature increase that would reduce efficiency.
Solution Approach 2:
Heat dissipation is moved from a two-dimensional surface problem to a three-dimensional volume solution by introducing the coolant chamber. This dimensional transition allows efficient thermal management in the high-density cell configuration, maintaining both high ACAR and acceptable operating temperatures.
3Reliability
If by-pass diodes are added to each cell for reliability, then system reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The by-pass diode is merged with the cell interconnection structure, sharing the same mounting substrate and electrical pathways. This integration reduces the number of separate components and simplifies the overall device complexity while maintaining the reliability benefit of individual cell protection.
Solution Approach 2:
The interconnection structure serves multiple functions: electrical connection between cells, mechanical support, and housing for the by-pass diode. This multi-functionality reduces the need for separate dedicated components, lowering device complexity and manufacturing cost while preserving reliability improvements.
4Power
If extensive interconnection structures are used to connect cells in series, then electrical output is improved, but dead space increases and ACAR decreases
Solution Approach 1:
Thin interconnection structures and flexible conductive materials are used to connect cells in series with minimal space occupation. These thin-film interconnects provide the necessary electrical pathways while occupying minimal area, thus maintaining high ACAR while achieving the required electrical output through series connection.
Solution Approach 2:
Interconnection pathways are routed through the third dimension (vertical/depth direction) rather than occupying horizontal plane space. This allows series connections to be made without increasing dead space in the two-dimensional active area, preserving high ACAR while achieving necessary electrical output.
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 solution achieves a high Active Cell Area Ratio (ACAR) of over 95%, optimizing energy conversion efficiency while reducing mechanical strain and costs, and ensuring reliable operation under varying illumination conditions.
Implementation Method 1
an array of photovoltaic cells for converting solar energy into electrical energy
Implementation Method 2
an assembly for extracting heat from the photovoltaic cell, the assembly comprising a coolant chamber positioned behind the exposed surface of the photovoltaic cell assembly
Implementation Method 3
a coolant inlet and a coolant outlet for coolant to be supplied into the chamber and for heated coolant to be removed from the chamber
Data Source
AI summary
A photovoltaic cell assembly suitable for use in a dense array concentrated photovoltaic cell module includes a plurality of photovoltaic cells mounted on a substrate and a by-pass diode associated with each cell to allow the cell to be by-passed in the electrical circuit in the event that the cell fails or has low illumination. The diodes are positioned in the shadows of the cells. The diodes provide direct pathways for heat and electricity from the cells to the substrate.