Triangular Photovoltaic Cell Layout for Lower Edge Defects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing photovoltaic cells face challenges in reducing edge defects and increasing production yields, particularly as wafer sizes grow, leading to suboptimal electrical performance and module design limitations due to conventional rectangular shapes.
Innovation Solution
Cleaving crystalline silicon wafers along the {110} plane to create non-rectangular, triangular photovoltaic cells, which reduces edge defects and allows for more flexible module designs with a flexible electro-conductive backsheet, enabling unique form factors and improved packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rectangular photovoltaic cells are used, then manufacturing process is simple and standardized, but edge defects increase and production yields decrease as wafer sizes grow
Solution Approach 1:
The patent applies asymmetry by changing the conventional rectangular shape of photovoltaic cells to triangular shapes. This asymmetric geometry reduces the perimeter-to-area ratio, thereby minimizing edge defects while maintaining effective light capture area. The triangular configuration allows for better packing arrangements that reduce the impact of edge-related manufacturing issues as wafer sizes increase.
Solution Approach 2:
The patent segments the photovoltaic module into multiple triangular cells arranged in specific patterns. This segmentation allows for optimized packing density and reduces the relative impact of edge defects across the entire module. By dividing the module into triangular units, the design achieves better utilization of the wafer area while minimizing harmful edge effects.
2Productivity
If rectangular photovoltaic cells are used, then module design is conventional and standardized, but packing density and light capture efficiency are suboptimal
Solution Approach 1:
The patent employs asymmetric triangular shapes instead of conventional rectangular cells, enabling more efficient packing arrangements within the module. This asymmetric design improves light capture efficiency by reducing gaps between cells and optimizing the active area utilization, while the modular triangular units maintain manageable design complexity.
Solution Approach 2:
The patent transitions from conventional two-dimensional rectangular arrangements to triangular configurations that utilize spatial dimensions more efficiently. This dimensional reconfiguration allows for better packing density and improved light capture pathways, enhancing overall productivity without excessively complicating the module design.
3Productivity
If larger wafer sizes are used, then fewer cells per module are needed, but edge defects increase and production yields decrease
Solution Approach 1:
The patent uses triangular cell shapes with optimized perimeter-to-area ratios to minimize edge defects associated with larger wafer sizes. This asymmetric geometry reduces the total edge length relative to the active area, thereby decreasing manufacturing precision challenges and improving production yields as wafer dimensions increase.
Solution Approach 2:
The patent segments larger wafers into multiple triangular cells that can be arranged to optimize both the number of cells per module and the minimization of edge defects. This segmentation strategy allows for maintaining high productivity with larger wafers while managing edge-related manufacturing challenges through careful geometric configuration.
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 production yields and module performance by reducing edge defects and enabling more efficient light capture and power generation through non-conventional shapes, accommodating irregularly shaped cells in modules and improving the fit on mounting rails.
Implementation Method 1
cleaving the silicon wafer along a {110} plane to form non-rectangular shapes from a starting square, such as triangular pieces
Implementation Method 2
Photovoltaic cells are electrical devices that convert light energy into electrical energy
Data Source
AI summary
An example of an apparatus to generate electricity from light with photovoltaic cells is provided. The apparatus includes a plurality of photovoltaic cells. The plurality of photovoltaic cells is to form a module. Furthermore, the apparatus includes an electro-conductive backsheet to connect the plurality of photovoltaic cells. The electro-conductive backsheet is to collect current from the plurality of photovoltaic cells. Each photovoltaic cell of the plurality of photovoltaic cells is formed on a silicon wafer by cutting along a {100} plane to provide a substantially square wafer and cleaving the substantially square wafer along a preferred cleavage plane.