Structured Solar Cell Connector for Light Diversion and Low Stress
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Solution Overview
Problem
Existing solar cell interconnection methods suffer from reflective loss of incident light, resistive loss, and increased thermomechanical stress, leading to reduced current generation and module durability.
Innovation Solution
A structured connector with a non-circular cross-sectional shape, featuring light diverting and scattering surface portions, is used to interconnect solar cells. This connector is designed to divert and scatter light away from the solar cells, reducing reflective losses and minimizing thermomechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If flat ribbons with rectangular cross-sections or wires with circular cross-sections are used as interconnectors, then electrical connection between solar cells is achieved, but reflective loss of incident light increases and current generation is reduced
Solution Approach 1:
The patent applies asymmetry by using a structured connector with a triangular cross-section instead of symmetric circular or rectangular shapes. This asymmetric geometry creates specific light diverting surface portions that redirect incident light away from the solar cell surface, reducing reflective loss and improving current generation while maintaining electrical connectivity.
Solution Approach 2:
The patent changes the geometric parameters of the interconnector by introducing a structured connector with specific triangular cross-sectional dimensions and surface orientations. These parameter changes optimize light diversion angles and reduce the connector's shadowing effect on incident light, thereby minimizing reflective loss and enhancing electrical performance.
2Reliability
If interconnectors are positioned on the solar cell surface, then electrical coupling is achieved, but thermomechanical stress on the photovoltaic material increases and durability is reduced
Solution Approach 1:
The asymmetric triangular cross-section of the structured connector distributes mechanical stress more evenly across the solar cell surface compared to circular or rectangular interconnectors. The specific geometric configuration reduces stress concentration points, thereby improving module durability while maintaining effective electrical coupling.
Solution Approach 2:
The structured connector incorporates curved surface portions that smoothly transition between different geometric features. These curved surfaces help distribute thermomechanical stress more uniformly across the contact area, reducing stress concentrations that would otherwise lead to material degradation and improved durability.
3Loss of energy
If interconnectors with conventional cross-sectional shapes are used, then electrical connection is established, but resistive loss increases and power output is reduced
Solution Approach 1:
The patent optimizes the cross-sectional parameters of the interconnector by using a triangular geometry with specific dimensions that maximize the conductive cross-sectional area while minimizing resistive loss. The structured configuration allows for better current distribution and reduced electrical resistance, thereby increasing power output.
Solution Approach 2:
The structured connector may incorporate composite material structures or multi-layer configurations that combine materials with different electrical and mechanical properties. This composite approach reduces resistive loss by optimizing current flow paths while maintaining structural integrity and thermal management.
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 structured connector enhances light utilization and current generation by effectively diverting and scattering light, while also reducing resistive losses and thermomechanical stress, thereby improving the efficiency and durability of photovoltaic modules.
Implementation Method 1
at least one light diverting surface portion that is oriented relative to the surface of the device component such that, in use, light directed at normal incidence relative to the surface of the device component is received by the at least one light diverting surface portion such that the received light is diverted towards an exposed adjacent surface of the device component
Implementation Method 2
at least one light scattering surface portion that is oriented relative to the surface of the device component such that, in use, light directed at normal incidence relative to the surface of the device component is received by the at least one light scattering surface portion such that the received light is scattered in a direction away from the device component
Data Source
AI summary
The present disclosure provides a structured connector for positioning on, and electrically coupling to, a surface of a device component. The connector has a bottom portion for contacting the surface of the device component and comprises an electrically conductive material. Further the connector has at least one light diverting surface portion that is oriented relative to the surface of the device component such that, in use, light directed at normal incidence relative to the surface of the device component is received by the at least one light diverting surface portion such that the received light is diverted towards an exposed adjacent surface of the device component. In addition, the connector has at least one light scattering surface portion that is oriented relative to the surface of the device component such that, in use, light directed at normal incidence relative to the surface of the device component is received by the at least one light scattering surface portion such that the received light is scattered in a direction away from the device component.