Solar Module Conductor Routing for Active Area
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Solution Overview
Problem
Conventional solar modules face challenges in maximizing the active photovoltaic area while ensuring sufficient insulation and maintaining high maximum back current, particularly in substrate-type designs, where conductor lines often lead to increased costs and reduced efficiency due to thick encapsulation and decreased active area.
Innovation Solution
The solar module design features conductor lines spaced minimally apart, with connectors on the rear side of the module, allowing conductor leads to extend along the second side for at least 25% of the spacing, and contact points located 20-50% from the end of the conductor lines, minimizing ohmic losses and enabling a single connection box to maximize active area without compromising insulation or back current capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor lines are arranged with sufficient spacing to ensure insulation, then insulation performance is improved, but active photovoltaic area is reduced
Solution Approach 1:
The patent transitions from planar conductor line arrangement to three-dimensional routing by extending conductor lines through the substrate thickness. This allows conductor leads to exit at different locations (front and rear sides), enabling closer spacing on the front surface while maintaining insulation through the substrate, thus resolving the contradiction between insulation requirements and active area maximization
Solution Approach 2:
The substrate serves as a thin film barrier that provides electrical insulation between conductor lines. By utilizing the substrate's insulating properties and routing conductors through it, the design achieves sufficient insulation with minimal spacing, thereby maximizing the active photovoltaic area
2Reliability
If thick conductor lines are used to maintain high maximum back current, then back current capability is improved, but encapsulation difficulty and cost increase
Solution Approach 1:
The patent applies different conductor line thicknesses at different locations: thick conductor lines are used only where high current density is required (at connection points), while thinner conductor lines are used in other areas. This localized differentiation maintains maximum back current capability while reducing overall material usage and encapsulation complexity
Solution Approach 2:
The design changes the conductor line cross-sectional area parameter along its length, using variable thickness to optimize both electrical performance and manufacturability. Thicker sections are placed only where necessary for high current carrying capacity, reducing encapsulation difficulty and cost
3Area of moving object
If conductor lines are arranged to maximize active area, then active photovoltaic area is improved, but insulation between conductor lines is compromised
Solution Approach 1:
The patent resolves the insulation issue by adding the substrate thickness dimension to the conductor routing. Conductor lines can be spaced minimally on the front surface to maximize active area, while insulation is provided through the substrate thickness, allowing conductor leads to exit at different sides without compromising electrical isolation
4Area of moving object
If conductor leads are extended through the substrate, then active area is maximized, but manufacturing complexity increases
Solution Approach 1:
The patent merges the conductor lead formation process with the substrate processing steps. Conductor leads are created by extending existing conductor lines through the substrate using standard thin-film deposition and patterning techniques, integrating the through-substrate connection functionality into the existing manufacturing flow without adding separate complex processing steps
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 enhances the active photovoltaic area, reduces ohmic losses, and simplifies encapsulation, while maintaining high insulation and back current capabilities, thus improving the overall efficiency and cost-effectiveness of the solar module.
Implementation Method 1
A solar module typically contains a plurality of solar cells connected in series, since each cell only produces a limited voltage that is lower than required as output voltage from the module
Implementation Method 2
The output voltage that is generated between the first and last solar cell, and is typically withdrawn by means of conductor lines, such as in the form of metal ribbons, which are also referred to as bus bars
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
A solar module comprising a sheet; a plurality of solar cells electrically connected in series between first and second conductor lines, and arranged on a first side of the sheet, wherein the first and second conductor lines each extend along a length on the sheet; a first conductor lead in electrical connection with the first conductor line and a second conductor lead in electrical connection with the second conductor line;and a through-hole in the sheet through which the first conductor lead extends to a second side of the sheet and a further through-hoIe through which the second conductor lead extends to the second side of the sheet.