Solar Cell Module Heat Spreading via Segmented Back Plate

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Solution Overview

Problem

Concentrator photovoltaic modules face high material and process costs due to the large area requirements for heat sinking and electrical connections, which increase ohmic losses and reduce efficiency, especially with the use of copper and complex multilayer technologies.

Innovation Solution

A solar cell module design where the solar cell assemblies (SCAs) handle electrical connections and initial heat spreading, while a separate, electrically insulated back plate takes over the majority of the heat spreading, reducing material usage and costs, and using a monolithic carrier structure with stamped regions for electrical interconnections and heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If copper is used for heat sinking in solar cell assemblies, then thermal conductivity is improved, but material costs increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcopper material cost

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The heat sinking function is segmented between the SCA (solar cell assembly) and the module base plate. The SCA handles local heat dissipation near the solar cell, while the module base plate provides additional heat sinking capacity. This segmentation allows reduction of expensive copper material in the SCA while maintaining overall thermal management effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The module base plate combines multiple functions: it serves as the mounting structure for SCAs, provides additional heat sinking capacity, and acts as the electrical insulation layer. By merging these functions into a single component, the patent eliminates the need for separate heat sink structures and reduces overall material costs.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the module base plate is electrically conductive, then electrical connectivity is improved, but ohmic losses increase due to parallel connection of all SCAs

Engineering Contradiction:

Improveelectrical connectivityVSAvoidohmic losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The module base plate has different electrical properties in different regions. The carrier structure regions are electrically conductive to provide connectivity, while the insulation layer regions are electrically insulating to prevent unwanted parallel connections. This local differentiation of electrical properties allows the base plate to provide both connectivity and insulation functions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces an insulation layer as an intermediary between the carrier structure and the rear side of SCAs. This insulation layer mediates the electrical connection, allowing the carrier structure to be conductive while preventing direct electrical contact between SCAs, thus avoiding parallel connections and ohmic losses.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If the SCA area is enlarged for heat spreading, then thermal management is improved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improveheat spreading capacityVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The module base plate is designed as a universal component that performs multiple functions: mechanical mounting of SCAs, electrical insulation, and heat sinking. By making the base plate multi-functional, the patent eliminates the need for separate heat sink components, thereby reducing manufacturing complexity while maintaining heat spreading capacity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces material costs, minimizes ohmic losses, and maintains high thermal conductivity, allowing for efficient heat dissipation and electrical connectivity, thus improving the efficiency and cost-effectiveness of concentrator photovoltaic modules.

Implementation Method 1

A certain part of this radiation energy is converted into electrical energy in the solar cell... the efficiency of the solar cell, which has increased rapidly in recent years and has now exceeded 40%

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

The high flux density of thermal energy in concentrator photovoltaics requires the solar cells to be coupled to an actively or passively cooled heat sink... the transfer of thermal energy from the cell to the various metal layers of the SCA

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2279531B1Solar cell module

Publication Date: 2018.01.03 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

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Figure 3

AI summary

The invention relates to a solar cell module comprising at least two interconnected assemblies (SCA) having solar cells and a bottom plate for a module comprising an electrically conductive carrier structure and an electrically insulated backing plate on at least the side facing the carrier structure. The assembly comprising the solar cell is constructed particularly small, thus having a low material usage of cooling body material, for example copper or aluminum, and thus allowing particularly cost effective production.