Solar Module Busbar Design for Power and Cost Balance
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Solution Overview
Problem
Current solar modules face challenges with high costs and low power output due to increased internal losses and occlusion area caused by the increasing number of busbars, which also lead to higher consumption of silver paste and electrode lines.
Innovation Solution
The solar module design includes a specific relationship between the diameter of the electrode line and the number of busbars, optimized within the range 116.55x^2 - 92.03x + 27.35 < y < 582.75x^2 - 425.59x + 92.58, where x is the diameter and y is the number of busbars, to balance power and cost by reducing the diameter of the electrode line and increasing the number of busbars effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of busbars is increased to reduce internal losses, then power output is improved, but occlusion area and manufacturing cost increase
Solution Approach 1:
The solar cell is divided into multiple independent regions with individual busbars, allowing current collection from different areas. This segmentation enables increased number of busbars (improving power output) while keeping each busbar narrow (reducing occlusion area per busbar), resolving the contradiction between power and occlusion.
2Power
If the number of busbars is increased to reduce internal losses, then power output is improved, but manufacturing cost increases due to higher consumption of silver paste and electrode lines
Solution Approach 1:
The patent optimizes the width parameter of each busbar and the number of busbars to achieve the best balance. By changing these parameters, the design increases the number of busbars for better power output while controlling the width to limit silver paste consumption, thus resolving the contradiction between power improvement and material cost increase.
3Loss of substance
If the diameter of electrode line is reduced to lower cost, then manufacturing cost is reduced, but current carrying capacity decreases
Solution Approach 1:
Instead of using a single thick electrode line, the design segments the current collection into multiple busbars with smaller individual electrode lines. This allows the use of thinner, cheaper electrode lines while maintaining total current carrying capacity through the multiplicity of parallel connections, resolving the contradiction between cost reduction and capacity maintenance.
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 optimization maximizes power output while minimizing costs by reducing the diameter of the electrode line and increasing the number of busbars within the specified range, thereby reducing internal losses and occlusion, leading to a balanced and efficient solar module performance.
Implementation Method 1
The solar cell is a core component of the photovoltaic module, which is a photoelectric semiconductor sheet that can directly generate power by using sunlight
Data Source
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AI summary
The present disclosure discloses a solar module, including solar cells, each solar cell includes a front surface and a rear surface arranged opposite to each other. The solar cell includes a semiconductor substrate and busbars located on one side of the semiconductor substrate, first electrode pads are provided at the busbars, a number of the first electrode pads ranges from 6 to 12. The solar module includes an electrode line with one end connected to the first electrode pads of the busbars on front surface of the solar cell and the other end connected to the first electrode pads of the busbars on rear surface of the adjacent solar cell. A relation between a diameter of the electrode line and a number of the busbars is 116.55x2-92.03x+27.35<y<582.75x2-425.59x+92.58, x denotes the diameter of the electrode line, and y denotes the number of the busbars.