Solar Cell Module Groove Isolation
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Solution Overview
Problem
The existing solar cell modules face reduced light energy conversion efficiency due to electrical connections between the lower and upper electrode layers at the edge portions of the substrate, which can lead to leakage currents affecting the active photoelectric conversion cells.
Innovation Solution
The solar cell module incorporates area-separating grooves and cell-separating grooves on the substrate to physically and electrically isolate the active area from the peripheral area, using a laser scribing process to form these grooves and create dummy cells that are spaced apart from the active cells, thereby preventing electrical connections and leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the lower electrode layer, semiconductor layer and upper electrode layer are formed on the entire surface of the substrate, then the coverage area of the photoelectric conversion cells is maximized, but the lower electrode layer and upper electrode layer become electrically connected at the edge portions, reducing light energy conversion efficiency
Solution Approach 1:
The patent applies segmentation by dividing the substrate into distinct active and peripheral regions through area-separating grooves. These grooves physically separate the lower and upper electrode layers at the edges, preventing electrical connection while maintaining full surface coverage for photoelectric conversion. This allows the electrode layers to extend across the entire substrate area without creating harmful electrical connections at the boundaries.
Solution Approach 2:
The patent extracts the problematic edge portions where electrical connections occur by removing material to form area-separating grooves. By taking out these specific regions where the lower and upper electrode layers would otherwise contact, the solution eliminates the electrical connection issue while preserving the photoelectric conversion functionality in the active areas.
2Ease of manufacture
If the lower electrode layer and upper electrode layer are electrically connected at the edge portion, then the manufacturing process is simplified, but leakage currents are generated that reduce the performance of photoelectric conversion cells
Solution Approach 1:
The area-separating grooves segment the substrate into active and peripheral zones, creating physical barriers that prevent electrical connections between electrode layers. This segmentation approach maintains manufacturing simplicity by using a straightforward groove formation process while effectively eliminating leakage current paths that would compromise device reliability.
Solution Approach 2:
The area-separating grooves act as intermediary structures between the lower and upper electrode layers. These grooves serve as physical mediators that prevent direct electrical contact while allowing the manufacturing process to remain simple and straightforward, thus protecting photoelectric conversion cell performance without complicating fabrication.
3Loss of energy
If area-separating grooves are formed to separate the active area from the peripheral area, then leakage currents are prevented, but the structural complexity of the solar cell module increases
Solution Approach 1:
The patent uses segmentation through area-separating grooves to prevent leakage currents. While this does increase structural complexity compared to a fully continuous electrode structure, the segmentation is achieved through a single, straightforward groove formation process that minimizes manufacturing steps. The grooves create clear physical boundaries that effectively block electrical leakage paths.
Solution Approach 2:
By extracting material to form area-separating grooves, the patent removes the sources of leakage currents. This extraction approach, while adding some structural complexity, uses a simple removal process rather than adding complex components, thus preventing energy loss through leakage currents with minimal increase in overall device complexity.
4Reliability
If multiple cell-separating grooves are formed in the active area, then electrical connections between adjacent cells are prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by forming multiple cell-separating grooves within the active area to electrically isolate adjacent photoelectric conversion cells. This segmentation ensures reliable electrical isolation between cells, preventing unwanted current paths. The grooves are formed in a systematic pattern that maintains manufacturing efficiency while achieving the required electrical isolation.
Solution Approach 2:
The patent merges the formation of area-separating grooves and cell-separating grooves into a coordinated manufacturing process. By combining these groove formation operations and optimizing their layout, the solution achieves reliable electrical isolation between cells and from peripheral areas while minimizing the overall manufacturing complexity.
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 solution enhances light energy conversion efficiency by preventing leakage currents from reaching the active area, thereby improving the overall performance of the solar cell module.
Implementation Method 1
forming the area-separating grooves and the first cell-separating grooves by irradiating a first laser beam onto the substrate on which the lower electrode layer is formed
Data Source
AI summary
A solar cell module includes a substrate, a lower electrode layer, a semiconductor layer and an upper electrode layer for an embodiment. The lower electrode layer may include a plurality of area-separating grooves separating the substrate into an active area and a peripheral area surrounding the active area, and a plurality of first cell-separating grooves formed in the active area. The semiconductor layer is formed on the lower electrode layer. The semiconductor layer includes a plurality of second cell-separating grooves that are spaced apart from the first cell-separating grooves. The upper electrode layer is formed on the semiconductor layer. The upper electrode layer includes a plurality of third cell-separating grooves that are spaced apart from the second separating grooves.