Textured PV Module Ribbons for Light Capture

Solution Overview

Problem

Photovoltaic (PV) module ribbons block a significant amount of useful light from reaching the photoactive areas of PV cells, reducing efficiency, and existing textured solutions increase cost and manufacturing complexity.

Innovation Solution

A method to directly impart a light-capturing texture to PV module ribbons by using a textured base during the manufacturing process, where heat energy from soldering transfers the texture to the ribbons, enhancing light scatter and capture without increasing costs or complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ribbons are used to connect PV cells, then electrical connection between cells is achieved, but light incident on photoactive areas is blocked

Engineering Contradiction:

Improveelectrical connectionVSAvoidlight blocking

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The ribbon surface is given a non-uniform texture with varying heights and densities in different local areas. This local quality variation allows light to be scattered and redirected toward the photoactive cell areas while maintaining electrical conductivity where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

A textured surface layer is introduced as an intermediary between the smooth ribbon surface and the incident light. This intermediary layer scatters light in beneficial directions while allowing the ribbon to maintain its electrical connection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If textured surfaces are applied to ribbons to reduce light blocking, then light capture improves, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvelight captureVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The texturing process is merged with the existing ribbon lamination step. The same heating and pressing operation that bonds the ribbon to the cell also transfers the texture from the cell surface to the ribbon surface, eliminating the need for separate texturing equipment and processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PV cell itself serves as the texturing tool. The textured surface of the PV cell directly imprints the texture onto the ribbon during lamination, using the cell's own surface characteristics to create the desired ribbon texture without requiring external texturing apparatus.

Inventive Principle:

Principle #25Self-service

3Loss of energy

If textured surfaces are applied to ribbons to reduce light blocking, then light capture improves, but manufacturing cost increases

Engineering Contradiction:

Improvelight captureVSAvoidmanufacturing cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The texturing process is merged with the existing ribbon lamination step. The same heating and pressing operation that bonds the ribbon to the cell also transfers the texture from the cell surface to the ribbon surface, eliminating the need for separate texturing equipment and processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PV cell itself serves as the texturing tool. The textured surface of the PV cell directly imprints the texture onto the ribbon during lamination, using the cell's own surface characteristics to create the desired ribbon texture without requiring external texturing apparatus.

Inventive Principle:

Principle #25Self-service

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 textured ribbons improve light scatter and capture, increasing the efficiency of PV cells and modules while maintaining production costs and complexity at current levels.

Implementation Method 1

transferred the light-capturing texture of the textured base to the first ribbon using heat energy released when the second photovoltaic module ribbon is coupled to the plurality of second electrodes

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10541344B2Texturing ribbons for photovoltaic module production

Publication Date: 2020.01.21 GCL SYST INTEGRATION TECH HONG KONG LTD

AI summary

A method for texturing a photovoltaic module ribbon on a photovoltaic cell including a plurality of first electrodes on a first side and a plurality of second electrodes on a second side, and coupling a first photovoltaic module ribbon to the plurality of first electrodes. The method also includes positioning the photovoltaic cell on a textured base having a texture embodied thereon, where the first photovoltaic module ribbon is substantially contacting the texture. The method further includes coupling a second photovoltaic module ribbon to the plurality of second electrodes, and transferring the texture of the textured base to the first ribbon using heat energy released when the second photovoltaic module ribbon is coupled to the plurality of second electrodes.