Shingled Solar Cell Busbar Extension for Corner Resistance
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Solution Overview
Problem
Conventional shingled solar cell modules face inefficiencies due to asymmetric busbar designs, leading to longer current collecting paths and higher resistance at chamfered corners, which affect power output and electroluminescence imaging.
Innovation Solution
The design includes extending front side and/or back side busbars at chamfered sections of solar cells, allowing these extensions to intersect with adjacent edges, thereby enhancing current collection capability and improving imaging and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional asymmetric busbar design is used in shingled solar cells, then manufacturing simplicity is maintained, but current collecting path length increases and resistance increases at chamfered corners
Solution Approach 1:
The patent applies asymmetry by extending the busbar specifically at the chamfered corner sections where it is needed most, rather than using a symmetric design. The extension is localized to the chamfered portions of the solar cell strips, creating an asymmetric busbar configuration that compensates for the reduced effective width at corners while maintaining manufacturing simplicity.
Solution Approach 2:
The busbar extension is applied locally only at the chamfered corner sections where the problem occurs, rather than extending the entire busbar uniformly. This local quality approach ensures that the current collection capability is enhanced precisely where the effective busbar width is reduced, without unnecessarily increasing complexity elsewhere in the design.
2Strength
If chamfered solar cell strips are used for shingled modules, then mechanical strength and handling are improved, but current collecting path length increases at corners affecting power output
Solution Approach 1:
The busbar extension is applied locally at the chamfered corner sections where power loss occurs, rather than modifying the entire solar cell structure. This localized extension compensates for the increased current path length at corners while preserving the mechanical advantages of chamfered strips for handling and module assembly.
Solution Approach 2:
The patent converts the potential harm of chamfered corners (increased resistance and power loss) into a benefit by strategically extending the busbar at these locations. The extension transforms the problematic areas into optimized current collection zones, turning the chamfered geometry from a liability into an asset for current management.
3Loss of energy
If busbar extension at chamfered sections is implemented, then current collection capability is enhanced, but device complexity increases
Solution Approach 1:
The busbar extension is implemented locally only at the chamfered corner sections rather than across the entire busbar structure. This localized approach enhances current collection where it is most needed while minimizing the increase in overall device complexity, as the extension is confined to specific high-impact areas.
Solution Approach 2:
The patent applies partial action by extending the busbar only at the necessary chamfered sections rather than uniformly across all busbar locations. This partial extension provides sufficient current collection improvement without unnecessarily increasing complexity in areas where the original design was already adequate.
Data Source
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AI summary
The present disclosure relates to solar cells for a shingled solar cell module, a shingled solar cell module, and a method of making solar cells for the shingled solar cell module. Said solar cell has a front side and a back side, a plurality of front side busbars being arranged on the front side, a plurality of back side busbars being arranged on the back side, the solar cell comprising a plurality of sections, each section comprising a front side busbar and a back side busbar located at edges thereof, the front side busbar of at least one section of the solar cell having an extension at one end or both ends, the extension extending along another edge of said at least one section intersecting with the above-mentioned edges. The shingled solar cell module is fabricated from solar cell strips split from the solar cell.