Parallel Interconnection of Solar Cells via Common Back Plane
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Solution Overview
Problem
The inefficiency in using circular solar cell wafers for photovoltaic arrays due to low fill factor and waste generation when converted into rectangular cells, along with the complexity and cost of high-efficiency solar cell production, necessitates a method to maximize wafer utilization while maintaining a high fill factor.
Innovation Solution
A solar cell assembly design featuring a support with a conductive layer comprising a first and second conductive portion, allowing for direct connection of solar cells in parallel, with bypass diodes for enhanced reliability and efficient heat dissipation, utilizing a large number of small rectangular solar cells to minimize waste and maximize surface area utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If circular solar cell wafers are converted into rectangular solar cells to achieve high fill factor, then surface area utilization is improved, but wafer material waste increases
Solution Approach 1:
The invention divides a single circular solar cell wafer into multiple smaller rectangular solar cells (e.g., 2x2 or 3x3 grid patterns). This segmentation allows the circular wafer to be fully utilized by creating multiple functional cells from what would traditionally be a single cell, thereby reducing material waste while maintaining high surface area utilization in the final array configuration.
Solution Approach 2:
The invention transitions from a single large rectangular cell per wafer to multiple smaller cells arranged in a grid pattern across the circular wafer surface. This dimensional reorganization allows more efficient packing of the circular wafer material while the resulting multiple cells can be arranged in various configurations to achieve 100% fill factor in the final array.
2Area of stationary object
If a large number of small solar cells are used to maximize wafer utilization, then fill factor is improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges multiple small solar cells created from a single circular wafer into a unified module structure. By integrating the electrical interconnections and encapsulation of multiple cells into a single manufactured unit, the complexity of handling numerous individual cells is reduced, making the manufacturing process more manageable while maintaining the high fill factor benefits.
3Loss of substance
If circular solar cells are used to minimize wafer waste, then wafer utilization is improved, but array fill factor decreases
Solution Approach 1:
The invention segments the circular wafer into multiple smaller rectangular cells that can be arranged in grid patterns. This segmentation allows the circular wafer shape to be fully utilized (minimizing waste) while the resulting rectangular cells can be configured in arrays with 100% fill factor, eliminating the space waste associated with circular cell arrangements.
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 waste, increases fill factor, and simplifies the manufacturing process by enabling easy interconnection of numerous small solar cells, improving the reliability and efficiency of solar cell assemblies while maintaining high wafer utilization.
Implementation Method 1
Photovoltaic devices, such as photovoltaic modules or 'CIC' (Solar Cell + Interconnects + Coverglass) assemblies, comprise one or more individual solar cells arranged to produce electric power in response to irradiation by solar light.
Implementation Method 2
the conductive layer, including the first conductive portion, can act as a thermal sink for the solar cells
Data Source
Figure 1~2
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AI summary
A solar cell assembly comprising a plurality of solar cells (104, 204) and a support, the support comprising a conductive layer. The conductive layer is divided into a first conductive portion (108, 208) and a second conductive portion (107, 207). Each solar cell of the plurality of solar cells comprising a front surface, a rear surface, and a first contact (111) in correspondence with the rear surface. Each one of the plurality of solar cells is placed on the first conductive portion with the first contact electrically connected to the first conductive portion so that the solar cells are connected in parallel through the first conductive portion. A second contact (105, 205) of each solar cell can be connected to the second conductive portion. The two conductive portions serve as busbars of the solar cell assembly.