High-Voltage Solar Module Layout With Sub-Cell Series Integration
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Solution Overview
Problem
High voltage solar modules face challenges in efficiently managing voltage and current while minimizing the need for power electronics, such as inverters or optimizers, due to limitations in existing photovoltaic cell configurations and interconnection methods.
Innovation Solution
The approach involves dicing solar cells into smaller sub-cells and using metallization as a handle for singulation, allowing for flexible module current and voltage configurations without increasing interconnections, and employing a monolithic metallization structure to tie sub-cells together, which reduces handling complexity and enhances reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solar cells are combined in traditional arrays to achieve high voltage, then voltage increases, but device complexity and power losses increase due to additional interconnections and power electronics requirements
Solution Approach 1:
The solar cell is divided into multiple sub-cells (e.g., 4 sub-cells) that are electrically isolated from each other. Each sub-cell functions as an independent photovoltaic unit, allowing series connection within the same cell substrate. This segmentation enables high voltage output (e.g., 72V) without requiring multiple separate cells and complex external interconnections.
Solution Approach 2:
Multiple sub-cells are merged into a single solar cell structure, sharing common substrates, encapsulants, and framing. The sub-cells are electrically connected through conductive pathways within the same cell, combining their voltage outputs while maintaining a unified module structure. This merging reduces the number of external interconnections and simplifies the overall system architecture.
2Temperature
If multiple solar cells are interconnected to achieve high voltage, then voltage increases, but power loss increases due to additional interconnection points
Solution Approach 1:
The cell is segmented into sub-cells with independent electrical pathways, allowing series connection without requiring physical connection between separate cells. This eliminates interconnection losses at cell-to-cell junctions while maintaining high voltage output through internal series arrangement of sub-cells.
3Ease of manufacture
If traditional photovoltaic modules are used, then manufacturing is simplified, but adaptability to different voltage requirements is limited
Solution Approach 1:
The solar cell incorporates switchable or reconfigurable electrical connections between sub-cells, allowing the same physical cell structure to be configured for different voltage outputs (e.g., 36V, 72V, or other configurations). This dynamic reconfigurability enables adaptation to various system requirements without requiring different cell types or additional interconnection hardware.
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 method enables the creation of high voltage modules with improved scalability, reduced power loss, and increased reliability, potentially eliminating the need for power electronics by simplifying the module design and interconnects, thereby enhancing efficiency and cost-effectiveness.
Implementation Method 1
Photovoltaic (PV) cells, commonly known as solar cells, are well known devices for conversion of solar radiation into electrical energy. Generally, solar radiation impinging on the surface of, and entering into, the substrate of a solar cell creates electron and hole pairs in the bulk of the substrate.
Data Source
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AI summary
A photovoltaic module can include a high voltage photovoltaic laminate that include a plurality of high voltage photovoltaic cells with each of the high voltage photovoltaic cells including a plurality of sub-cells. A boost-less conversion device can be configured to convert a first voltage from the high voltage photovoltaic laminate to a second voltage.