Shingled Solar Cell Module Conductive Adhesive Thermal Management

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional solar cell modules face inefficiencies in heat management and hot spot prevention due to the lack of effective heat conduction and parallel bypass diodes, leading to reduced reliability and performance.

Innovation Solution

The implementation of shingled solar cell modules with overlapping and conductively bonded silicon solar cells, utilizing a conductive adhesive for series connection and thermal management, and the use of flexible electrical interconnects for accommodating thermal expansion and providing mechanical compliance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional solar cell modules are used with traditional wiring and spacing, then manufacturing and assembly are simpler, but heat management is ineffective and hot spots occur reducing reliability

Engineering Contradiction:

Improvemodule reliabilityVSAvoidmodule structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges electrical connection and thermal management functions into a single conductive adhesive material. This adhesive simultaneously bonds solar cells in series connection and conducts heat away from the cells, eliminating the need for separate wiring and heat sink structures. The merging of these functions resolves the contradiction by improving reliability through effective heat management while avoiding additional structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive adhesive serves multiple functions: electrical connection, thermal conduction, and mechanical bonding. This multi-functionality allows the module to achieve effective heat management and improved reliability without adding complex separate systems for each function, thus resolving the contradiction between reliability improvement and structural complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If solar cells are arranged with gaps for traditional wiring, then assembly is easier, but active area is reduced and efficiency decreases

Engineering Contradiction:

Improveenergy conversion efficiencyVSAvoidassembly ease

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent extracts the wiring function from separate physical wires and integrates it into the conductive adhesive material itself. This allows solar cells to be arranged in continuous series connection without gaps for wire routing, maximizing active area and efficiency while maintaining ease of manufacture through simplified assembly processes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the physical state and properties of the bonding material to be electrically conductive, allowing it to serve dual purposes of mechanical bonding and electrical connection. This parameter change enables continuous cell arrangement without wiring gaps, improving efficiency while simplifying assembly.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If rigid connections are used between solar cells, then structural stability is better, but thermal expansion mismatch causes stress and failure

Engineering Contradiction:

Improvestructural stabilityVSAvoidconnection reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent employs a flexible conductive adhesive layer between solar cells that can accommodate thermal expansion and contraction. This flexible bonding medium maintains structural stability while relieving stress from thermal mismatch, preventing connection failure and improving reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention changes the mechanical properties of the bonding material to provide flexibility and compliance. The conductive adhesive has appropriate modulus and thickness to allow thermal expansion mismatch without generating excessive stress, thus maintaining both structural stability and connection reliability.

Inventive Principle:

Principle #35Parameter changes

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 enhances heat conduction, prevents hot spots, and improves the reliability and efficiency of solar cell modules by ensuring safe and reliable operation, while reducing the need for bypass diodes.

Implementation Method 1

enhances heat conduction, prevents hot spots

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

accommodating thermal expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

flexible electrical interconnects for accommodating thermal expansion

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 4

solar cell module

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS11482639B2Shingled solar cell module

Publication Date: 2022.10.25 MAXEON SOLAR PTE LTD

AI summary

A high efficiency configuration for a solar cell module comprises solar cells conductively bonded to each other in a shingled manner to form super cells, which may be arranged to efficiently use the area of the solar module, reduce series resistance, and increase module efficiency.