Solar Sub-Cell Matrix Connections for Lower PV Power Loss
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Solution Overview
Problem
Solar array modules experience power losses due to busbars, solder points, conductors, and junction boxes, which reduce the overall output power of PV panels, and existing non-monolithic solar array configurations do not effectively minimize these losses.
Innovation Solution
A non-monolithic solar array module system with PV solar sub-cells interconnected in a crisscross configuration, where regular-sized solar cells are replaced by smaller sub-cells, allowing for passive rerouting of current in case of malfunction and eliminating the need for a DC/DC converter, thereby reducing power losses and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If regular-sized solar cells are used, then the current output is high, but power losses in conductors and solder points increase significantly
Solution Approach 1:
The patent divides regular-sized solar cells into multiple smaller sub-cells (e.g., 36 smaller sub-cells replacing traditional larger cells). This segmentation reduces the current magnitude in each cell while maintaining total power output, thereby reducing I²R losses in conductors and solder points. The smaller sub-cells are arranged in series-parallel configurations to achieve the desired voltage and current characteristics with minimized power losses.
2Loss of energy
If smaller sub-cells are used, then power losses are reduced, but the device complexity increases due to more interconnections
Solution Approach 1:
The patent merges multiple smaller sub-cells into modular units or blocks that can be interconnected in standardized patterns. This merging approach reduces the overall complexity by creating repeatable modules rather than individually connecting each sub-cell. The modular design allows for systematic interconnection while maintaining the power loss reduction benefits of smaller cell sizes.
3Device complexity
If conventional solar cell configurations are used, then the structure is simple, but DC/DC converters are required which add device complexity and reduce efficiency
Solution Approach 1:
The patent changes the electrical parameters (voltage, current, and resistance distribution) of the solar cell array by using smaller sub-cells in specific series-parallel configurations. This parameter optimization allows the system to operate directly at compatible voltage levels for inverters or battery chargers, eliminating the need for DC/DC converters and their associated energy losses and complexity.
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
The crisscross matrix configuration reduces power losses by minimizing current flow through conductive losses, eliminates the need for a DC/DC converter, and enhances overall panel energy output by approximately 3% without requiring additional voltage conversion, allowing direct connection to inverters or battery chargers.
Implementation Method 1
A solar power generation system for providing a predetermined operating power level and predetermined operating voltage level requirement... each of the at least one solar-array panels includes a multiplicity of PV solar sub cells... Each of the PV solar sub cell is physically smaller than a regular PV solar cell
Data Source
AI summary
A solar power generation system for providing a predetermined operating power level and predetermined operating voltage level requirement is provided. The system includes at least one solar-array panel. Each of the solar-array panels includes a multiplicity of PV solar sub cells. A preconfigured number of the PV solar sub cells are electrically connected in series to form a serial-unit or each forming an individual serial unit having just one PV solar sub cell. A preconfigured number of the serial units are electrically connected in series to form a string of serial-units. The PV solar sub cells are also connected in parallel to neighboring sub cells to form a crisscross matrix array that facilitates bypassing malfunctioning serial units, thereby improving the performance of the system. A PV solar sub cell is at least 50% smaller in area than a regular PV solar cell.