Shingled Solar Cells with Non-Linear Edges

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Solution Overview

Problem

Conventional solar devices with straight edges require more material to achieve the same power rating due to shading issues from connection pads, leading to inefficiencies in material usage and increased costs.

Innovation Solution

The use of solar cells arranged in a shingled manner with non-linear edges, where adjacent cells overlap along protruding portions, allowing for reduced material usage by minimizing the overlap area while maintaining electrical connectivity through contact pads located in these protruding areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If solar cells are arranged with straight edges and conventional overlapping, then electrical connectivity is achieved, but material usage increases due to larger overlap areas required for connection pads

Engineering Contradiction:

Improvematerial usageVSAvoidedge geometry complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent applies curvature to the solar cell edges by using sinusoidal or non-linear wave patterns instead of straight lines. This curved edge design allows contact pads to be positioned in protruding portions where they do not shade adjacent cells, reducing the required overlap area from conventional straight-edge designs while maintaining electrical connectivity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent implements local quality by concentrating the contact pads in specific protruding portions of the non-linear edges rather than distributing them uniformly. This localized arrangement allows the overlap area to be minimized in regions where contact pads are absent, while maintaining connectivity only where geometrically optimal.

Inventive Principle:

Principle #3Local quality

2Power

If larger overlap areas are used for connection pads, then electrical connectivity is ensured, but shading increases and power output decreases

Engineering Contradiction:

Improvepower outputVSAvoidelectrical connectivity

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The sinusoidal edge design creates protruding portions that position contact pads away from areas that would shade adjacent cells. This curvature-based arrangement reduces shading losses while keeping connection pads in locations that ensure reliable electrical connectivity through the overlap regions.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Productivity

If conventional straight-edge solar cells are used, then manufacturing is simpler, but more material is required to achieve the same power rating

Engineering Contradiction:

Improvepower rating efficiencyVSAvoidedge fabrication complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The sinusoidal edge pattern can be manufactured using standard solar cell fabrication techniques such as laser cutting or mechanical sawing with guided templates. While the edge geometry is more complex than straight lines, the manufacturing process remains feasible with moderate complexity increases, justified by the significant material savings and power rating improvements.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Loss of substance

If overlap area between adjacent solar cells is reduced, then material usage decreases, but electrical connection reliability may be compromised

Engineering Contradiction:

Improvematerial consumptionVSAvoidelectrical connection reliability

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent applies local quality by concentrating contact pads in specific protruding portions of the non-linear edges. This localized arrangement allows the overlap area to be minimized in regions where contact pads are absent, while maintaining connectivity only where geometrically optimal, thus reducing material consumption without compromising connection reliability.

Inventive Principle:

Principle #3Local quality

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 approach reduces material consumption by up to 2.5 solar cells per string without compromising power output, as the non-linear edges minimize shading and allow for efficient electrical connection, thereby optimizing the production of solar devices.

Implementation Method 1

Photovoltaic (PV) cells, commonly known as solar cells, are well-known devices for converting solar radiation into electrical energy

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS11695086B2Shingled solar cells overlapping along non-linear edges

Publication Date: 2023.07.04 MAXEON SOLAR PTE LTD

AI summary

Solar devices and methods for producing solar devices are disclosed. In some examples, a solar device includes solar cells arranged in a shingled manner such that adjacent long edges of adjacent ones of the solar cells overlap. The adjacent long edges have a non-linear shape that has protruding portions. The solar device includes contact pads arranged in the protruding portions of the adjacent long edges such that the contact pads of the adjacent ones of the solar cells are electrically connected.