Monocrystalline Silicon Wafer Extension Edge for Dense PV Cell Overlap
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Solution Overview
Problem
Existing photovoltaic modules with monocrystalline and polycrystalline silicon wafers suffer from low efficiency and power output due to low arrangement density of cell slices, sheet gaps, and overlapping areas that shield light during stitch-welding.
Innovation Solution
The silicon wafers are designed with extension edges that overlap below adjacent wafers during welding, eliminating sheet gaps and increasing arrangement density, using leftovers to form ribbon-shaped structures that enhance power generation and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cell slices are arranged with sheet gaps between them, then manufacturing is simpler, but arrangement density is low and efficiency is reduced
Solution Approach 1:
The invention transitions from traditional side-by-side arrangement to multi-layer stacked arrangement, utilizing the vertical dimension to increase arrangement density. Cell slices are arranged in multiple layers with overlapping extension edges, effectively transforming a 2D arrangement problem into a 3D spatial optimization solution.
Solution Approach 2:
The extension edges of cell slices overlap and nest between adjacent cell slices, creating an interlocked structure. This nesting arrangement eliminates sheet gaps while maintaining structural integrity, allowing cell slices to be tightly packed in multiple layers without requiring complex manufacturing processes.
2Quantity of substance
If stitch-welding is used to increase arrangement density, then arrangement density improves, but overlapping areas shield light and reduce output power
Solution Approach 1:
The cell slice is segmented into a main body area and an extension edge area. The main body maintains full light transmission for power generation, while the extension edge serves as a non-active welding region that overlaps with adjacent slices without compromising the light-receiving capability of the main bodies.
Solution Approach 2:
Different regions of the cell slice are assigned different functions: the main body region is optimized for light absorption and power generation with full transparency, while the extension edge region is optimized for mechanical connection and welding with overlapping capability. This local differentiation allows high-density arrangement without sacrificing output power.
3Ease of manufacture
If traditional square slices are used, then manufacturing is standard, but sheet gaps form and efficiency is low
Solution Approach 1:
The extension edges are pre-formed as integral parts of the cell slices during the manufacturing process, before assembly. This preliminary formation of overlapping edges ensures that when cell slices are stacked and welded, the extension edges automatically fill the gaps between main bodies, eliminating the need for additional gap-filling operations and maximizing efficiency.
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 solution increases the power and efficiency of photovoltaic modules by reducing sheet gaps and enhancing arrangement density, while utilizing silicon material more effectively and reducing production costs.
Implementation Method 1
the extension edge is used to overlap below the adjacent monocrystalline silicon wafer during welding
Data Source
AI summary
The invention discloses a silicon wafer and a preparation method therefor, a cell sheet, a cell slice, a cell string, and a photovoltaic module. The monocrystalline silicon wafer comprises a silicon wafer main body and an extension edge that extends outwards from an edge of the silicon wafer main body, the silicon wafer main body is a right-angled square slice or a rounded square slice, the extension edge is a ribbon-shaped structure parallel to the edge of the silicon wafer main body, and the extension edge is used to overlap below the adjacent monocrystalline silicon wafer during welding. By making the extension edge overlap below the adjacent cell sheet or cell slice, a sheet gap is reduced, an increase in an arrangement density of the cell sheets or cell slices is facilitated, and an efficiency of a photovoltaic module is increased. Since the adjacent cell sheet or cell slice shields the extension edge rather than the silicon wafer main body, the area of the cell sheet or cell slice involved in power generation is increased, and an increase in the power of the photovoltaic module is facilitated.