Solar Module Interconnection Layout for Low Shading and Cell Stress
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Solution Overview
Problem
Conventional solar modules face efficiency losses due to shading by wide cell connectors and potential damage from cross-connectors, which can cause fractures or cracks in solar cell substrates.
Innovation Solution
Implement a multi-busbar interconnection system using narrow wires with flattened regions at terminal substrates to connect adjacent solar cell substrates in series, positioning cross-connectors on the rear side to avoid mechanical overload and reduce shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If wide cell connectors are used to connect solar cells in series, then electrical series resistance is reduced, but light absorption efficiency decreases due to increased shading
Solution Approach 1:
The patent divides the single wide cell connector into multiple narrow wire interconnections. Each wire connects to a separate busbar on the solar cell, creating multiple parallel electrical pathways. This segmentation reduces the total shaded area while maintaining low series resistance through parallel conduction paths
Solution Approach 2:
The patent transitions from a two-dimensional wide connector layout to a three-dimensional multi-wire configuration. Wires are routed through the encapsulation material in multiple layers and angles, allowing electrical connection without requiring wide surface area, thus reducing shading while maintaining conductivity
2Reliability
If cross-connectors are positioned on the front side of solar cell substrates, then electrical connection between strings is achieved, but light absorption area is reduced due to shading
Solution Approach 1:
The patent inverts the conventional approach by positioning cross-connectors on the rear side of solar cell substrates instead of the front side. This allows the front surface to be fully utilized for light absorption while the rear side handles electrical interconnections, eliminating the shading problem entirely
3Ease of manufacture
If conventional interconnection methods are used during encapsulation, then manufacturing is simplified, but mechanical damage occurs to solar cell substrates due to compression forces
Solution Approach 1:
The patent incorporates cushioning elements into the encapsulation structure that are positioned to protect solar cell substrates during compression. These elements absorb and distribute mechanical stresses, preventing direct transmission of compressive forces to the fragile solar cells while maintaining the simplicity of the encapsulation process
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
Enhances efficiency by minimizing shading and reducing mechanical stress on solar cell substrates, ensuring reliable and durable solar module performance.
Implementation Method 1
Solar cells are used to convert light directly into electrical energy using the photovoltaic effect
Data Source
AI summary
A solar module and a method of manufacturing the same. The solar module has a plurality of solar cell arrays, a cross-connector and an encapsulation. Each of the solar cell arrays includes solar cell substrates with contact structures and an interconnection structure that includes a plurality of round or rounded wires. Some of the wires have a flatter cross-section in a flattened region than the same wires in a non-flattened region adjacent to the flattened region and/or than other wires. The flattened region is located at and/or near an edge of a terminal solar cell substrate adjacent to a portion of the contacting surface of a rear side of the solar cell substrate. At least two strings of solar cell arrays are arranged side by side and interconnected by means of the cross-connector.