Shingled Solar Cell Manufacturing via Segmentation and Electrostatic Handling
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Solution Overview
Problem
The efficiency of solar cells is reduced due to the presence of electrical contacts such as fingers and busbars on the front surface, which decreases the active area exposed to sunlight, thereby reducing the module power of solar cell modules.
Innovation Solution
An apparatus and method for manufacturing shingled solar cell arrangements by separating solar cells into smaller pieces based on geometric and physical properties, allowing for the creation of solar cell arrangements with overlapping pieces that increase the active area and improve efficiency by avoiding low-quality pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If solar cells are used with traditional electrical contacts (fingers and busbars) on the front surface, then the module power is reduced due to decreased active area, but the manufacturing process is simpler
Solution Approach 1:
The solar cell is divided into multiple smaller solar cell pieces through a separation device. This segmentation allows the active area to be maximized by removing or minimizing the electrical contacts on each piece, while the pieces are subsequently arranged in series configuration to achieve the desired voltage and power output. The segmentation principle directly resolves the contradiction by enabling higher module power through increased active area utilization.
Solution Approach 2:
The invention transitions from a two-dimensional planar arrangement of solar cells with front-surface contacts to a three-dimensional stacked arrangement of separated solar cell pieces. By stacking multiple pieces in series with overlapping configurations, the system achieves higher power output while minimizing the impact of electrical contacts on the active area, effectively utilizing the vertical dimension to resolve the power-complexity contradiction.
2Productivity
If solar cells are separated into smaller pieces and arranged in series, then the active area is increased and efficiency improved, but the manufacturing complexity increases
Solution Approach 1:
The solar cell is systematically divided into multiple standardized pieces using a separation device, which enables efficient processing and arrangement. The segmented pieces can be independently optimized for maximum active area while maintaining electrical functionality through series connection. This segmentation approach improves efficiency by eliminating dead space and contact area losses.
Solution Approach 2:
The separation of solar cells into pieces is performed as a preliminary action before the assembly process. By pre-separating the cells and preparing them in advance, the subsequent assembly into series configurations becomes more streamlined and manageable, reducing the overall manufacturing complexity despite the increased number of components.
3Power
If solar cell pieces are separated and allocated based on geometric and physical properties, then the module power is optimized, but the measurement and sorting complexity increases
Solution Approach 1:
Solar cell pieces are sorted and allocated to specific positions in the series arrangement based on their local geometric and physical properties. This ensures that each piece contributes optimally to the overall module power, with high-quality pieces placed in critical positions. The local quality principle enables maximized power output by matching piece characteristics to their functional requirements.
Solution Approach 2:
The invention utilizes changes in geometric and physical parameters of solar cell pieces as sorting criteria. By measuring and categorizing pieces based on these parameters (such as size, shape, electrical properties), the system optimizes the arrangement to achieve maximum module power while managing the measurement complexity through systematic parameter-based classification.
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 method increases the module power of solar cell modules by optimizing the active area and improving the overall efficiency of the solar cell arrangements by ensuring that only high-quality pieces are used, thereby enhancing the performance.
Implementation Method 1
an electric arrangement configured for providing an electrostatic force for holding the at least one solar cell element on the support element
Data Source
AI summary
The present disclosure provides a support device for conveying at least one solar cell element in a transport direction, wherein the support device comprises a support element configured for supporting the at least one solar cell element and an electric arrangement configured for providing an electrostatic force for holding the at least one solar cell element on the support element.