Shingled Solar Cells with Non-Linear Edges

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Solution Overview

Problem

Conventional solar cell designs with straight edges require more material to achieve a given power rating, leading to potential shading issues and inefficiencies in active area usage due to the need for discrete connection pads, which can be mitigated by using solar cells with non-linear edges that overlap in a shingled manner.

Innovation Solution

The design involves arranging solar cells in a shingled configuration where the ends of adjacent cells overlap along non-linear edges, reducing material usage by minimizing the overlap area while maintaining electrical connectivity through conductive bonding materials, and encapsulating these cells in a solar module with a polymer encapsulant and glass sheets for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If solar cells with straight edges are used, then manufacturing and assembly are simpler, but more material is required and shading issues occur

Engineering Contradiction:

Improveease of manufactureVSAvoidmaterial usage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent applies curvature to the edges of solar cells by using sinusoidal or non-linear edge profiles instead of straight edges. This curved edge design allows adjacent cells to overlap in a shingled configuration where the curved surfaces interlock, reducing the total overlap area required while maintaining structural integrity and electrical connectivity. The curved edges enable more efficient packing of cells within the module boundaries.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent segments the solar cell edges into distinct functional zones: active photovoltaic areas and non-active edge areas. By dividing the cell structure and using non-linear segmentation of the edges, the design optimizes the arrangement where only necessary portions overlap, reducing material waste while maintaining functionality.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If solar cells with straight edges are used, then assembly is easier, but active area usage efficiency decreases

Engineering Contradiction:

Improveassembly easeVSAvoidactive area usage efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The sinusoidal or non-linear edge profiles enable more efficient spatial utilization of active cell areas. The curved edges allow cells to be arranged in a shingled pattern that maximizes the exposed active surface area while minimizing the overlap regions, thereby improving the ratio of productive active area to total material used.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Loss of substance

If overlap area is reduced to save material, then material usage improves, but electrical connectivity may be compromised

Engineering Contradiction:

Improvematerial usageVSAvoidelectrical connectivity

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent applies different properties to different parts of the cell structure. The edge regions are designed with non-linear profiles that provide both mechanical interlocking and electrical connection functions, while the central active areas maintain optimal photovoltaic properties. This local differentiation allows reduced overall overlap while maintaining necessary electrical connectivity at specific locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces conductive bonding materials as intermediaries between overlapping cell edges. These bonding materials serve dual functions: providing mechanical adhesion to hold cells in the shingled configuration and ensuring electrical connectivity between adjacent cells, thereby maintaining reliability even with reduced overlap areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 usage by up to 2.5 solar cells per string without compromising power output, enhances efficiency by minimizing shading, and allows for more compact solar device designs with improved power generation capabilities.

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

Implementation Method 2

the overlapping portions are electrically connected to one another by a conductive bonding material

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3491674B1Shingled solar cells overlapping along non-linear edges

Publication Date: 2022.01.12 MAXEON SOLAR PTE LTD

Figure 1A
Figure 1B
Figure 1C~1D

AI summary

Solar devices and methods for producing solar devices are disclosed. Aspects of the disclosure provide a solar device that includes at least a first solar cell and a second solar cell. The first solar cell is configured to have a first edge of a non-linear shape with protruding portions and have first one or more contact pads arranged in the protruding portions. The second solar cell is configured to overlap with the first solar cell at the protruding portions. The second solar cell includes second one or more contact pads that are aligned with the first one or more contact pads to electrically connect the first solar cell and the second solar cell.