Solar Cell Dead Zone Reflection for Higher Light Utilization
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Solution Overview
Problem
The challenge in solar cell production is to enhance photovoltaic conversion efficiency, as conventional methods are limited in reducing the dead zone area and thus cannot significantly improve efficiency due to production process constraints.
Innovation Solution
A solar cell design incorporating a reflection portion on the dead zone surfaces to reflect incident light onto a packaging component, which then directs it to the sub-cells for conversion, thereby increasing light utilization and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dead zone area is reduced to improve photovoltaic conversion efficiency, then the light utilization rate increases, but the production process complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent converts the harmful dead zone (which causes light loss) into a beneficial light-reflecting structure by adding a reflection layer. Instead of simply reducing the dead zone area, the invention utilizes the dead zone as a light management component that redirects incident light to the sub-cell, transforming waste into useful photovoltaic conversion area.
Solution Approach 2:
The reflection layer acts as an intermediary component between the dead zone and the sub-cell. It mediates the light path by reflecting incident light from the dead zone toward the sub-cell, enabling light utilization without requiring direct contact or integration between the dead zone and photovoltaic structure.
2Productivity
If conventional methods are used to reduce dead zone area, then photovoltaic conversion efficiency improves slightly, but the manufacturing cost and process difficulty increase
Solution Approach 1:
The invention transforms the dead zone from a manufacturing constraint into a functional light-reflecting structure. By adding a reflection layer to the existing dead zone, the patent achieves improved light utilization without requiring complex manufacturing processes or significant redesign of the production line.
Solution Approach 2:
The patent changes the optical parameter of the dead zone by introducing a reflection layer with specific reflective properties. This parameter change enables the dead zone to reflect light effectively while maintaining the same physical structure and manufacturing process, avoiding the need for complex geometric modifications.
3Productivity
If the reflection portion is added to the dead zone to reflect light, then light utilization rate increases, but the device structure becomes more complex
Solution Approach 1:
The reflection layer serves multiple functions simultaneously: it reflects incident light from the dead zone, protects the underlying structure, and can be integrated with existing encapsulation materials. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in structural complexity.
Solution Approach 2:
The invention achieves improved light utilization by changing the optical parameter (reflectivity) of the dead zone surface through the addition of a reflection layer, rather than changing the physical geometry or adding complex three-dimensional structures. This approach minimizes structural complexity while maximizing optical performance.
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 design significantly enhances photovoltaic conversion efficiency and improves the reliability and stability of the solar cell by effectively utilizing otherwise wasted light, while maintaining a cost-effective and simplified manufacturing process.
Implementation Method 1
a reflection portion, disposed on at least a part of surfaces of the dead zone, and configured to reflect incident light radiated on the dead zone
Implementation Method 2
the packaging component reflects the incident light, which is reflected by the reflection portion, to a surface of the sub-cell
Implementation Method 3
the sub-cell can perform photovoltaic conversion by using such light, thereby improving the photovoltaic conversion efficiency of the solar cell
Data Source
AI summary
This application relates to a solar cell and a manufacturing method thereof, a photovoltaic module, and an electrical device. The solar cell includes: a plurality of sub-cells, where the plurality of sub-cells are electrically connected to each other; a dead zone, disposed between two adjacent sub-cells; a reflection portion, disposed on at least a part of surfaces of the dead zone, and configured to reflect incident light radiated on the dead zone; a packaging component, disposed on a side of the reflection portion away from the dead zone, and configured to reflect the incident light, which is reflected by the reflection portion, to a surface of the sub-cell to convert the incident light into electrical energy.