Thin-Film PV Module Serial Interconnection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thin-film photovoltaic (PV) modules face efficiency and cost challenges compared to silicon-based modules, and existing solutions do not effectively address the need for efficient and cost-effective manufacturing and installation methods for thin-film PV systems.
Innovation Solution
The development of longitudinally continuous PV modules with serially and redundantly interconnected thin-film PV strips, using a flexible top and bottom layer with conductive strips for efficient power collection and interconnection, and a method for determining optimal installation angles and reflector shapes based on site-specific data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin-film PV materials are used instead of silicon-based modules, then manufacturing cost is reduced, but conversion efficiency decreases
Solution Approach 1:
The PV module is divided into multiple discrete strips of thin-film PV material arranged in parallel, with each strip independently connected to conductive strips. This segmentation allows for optimized light trapping in each strip while maintaining low manufacturing costs through continuous thin-film deposition processes.
Solution Approach 2:
The patent introduces vertically extending reflector structures behind the thin-film PV strips to create optical pathways in the vertical dimension. This allows light to be trapped and redirected multiple times through the thin-film material, significantly enhancing absorption and conversion efficiency without increasing the horizontal footprint or material cost.
2Productivity
If multiple thin-film PV strips are arranged in parallel with conductive strips, then power collection efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple conductive strips are merged into a single continuous conductive strip that runs the length of the module, collecting current from all parallel PV strips simultaneously. This merging simplifies the interconnection structure by eliminating the need for multiple separate connection paths while maintaining high power collection efficiency from all strips.
Solution Approach 2:
The continuous conductive strip serves multiple functions: it acts as an electrical collector for all PV strips, provides structural support for the parallel strip arrangement, and facilitates simplified wiring to external circuits. This multi-functionality reduces overall device complexity while maintaining high productivity.
3Reliability
If vertically extending reflector structures are added behind PV strips, then light absorption is enhanced, but manufacturing complexity increases
Solution Approach 1:
The reflector structures are implemented as thin-film coatings deposited directly onto the rear surface of the substrate, forming flexible, light-weight reflective layers. This approach enhances light absorption through multiple internal reflections while maintaining ease of manufacture through standard thin-film deposition techniques, avoiding the need for complex rigid reflector components.
Solution Approach 2:
The patent uses composite material structures combining transparent dielectric layers with metallic reflective layers to create the vertically extending reflector structures. These composite materials provide both the necessary optical reflection properties and mechanical stability, while being manufacturable through sequential thin-film deposition processes that integrate smoothly with existing production lines.
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 approach enhances the efficiency and cost-effectiveness of thin-film PV modules by improving power collection and installation efficiency, while allowing for customized installation configurations to maximize energy output.
Implementation Method 1
a plurality of strips of thin-film photovoltaic (PV) material arranged to be spaced apart from and substantially parallel to one another
Implementation Method 2
The top layer includes a plurality of top layer conductive strips... The bottom layer includes a plurality of bottom layer conductive strips... serially and redundantly interconnecting the strips of thin-film PV material together
Implementation Method 3
The shaped interconnecting regions are configured to reflect and concentrate reflected light onto the PV strips
Data Source
AI summary
A method of forming a longitudinally continuous photovoltaic (PV) module includes arranging strips of thin-film PV material to be spaced apart from and substantially parallel to each other. The method also includes laminating a bottom layer to a first surface of the strips of thin-film PV material, the bottom layer including multiple bottom layer conductive strips. The method also includes laminating a top layer to a second surface of the strips of thin-film PV material opposite the first surface, the top layer including multiple top layer conductive strips. Laminating the bottom layer to the first surface and laminating the top layer to the second surface includes serially and redundantly interconnecting the strips of thin-film PV material together by connecting each one of the strips of thin-film PV material to a different one of the bottom layer conductive strips and a different one of the top layer conductive strips.