Solar panel

Patent metadata

Field	Value
Publication number	US-10084104-B2
Application number	US-201615210516-A
Country	US
Kind code	B2
Filing date	Jul 14, 2016
Priority date	Aug 18, 2015
Publication date	Sep 25, 2018
Grant date	Sep 25, 2018

Abstract

A high efficiency configuration for a solar cell module comprises solar cells arranged in an overlapping shingled manner and conductively bonded to each other in their overlapping regions to form super cells, which may be arranged to efficiently use the area of the solar module. Rear surface electrical connections between solar cells in electrically parallel super cells provide alternative current paths (i.e., detours) through the solar module around damaged, shaded, or otherwise underperforming solar cells.

First claim

What is claimed is:

1. A solar module comprising:
a plurality of super cells arranged in two or more physically parallel rows with the rows electrically connected to each other in parallel, each super cell comprising a plurality of rectangular silicon solar cells arranged in line with long sides of adjacent silicon solar cells overlapping and conductively bonded directly to each other to electrically connect the silicon solar cells in series; and
a plurality of detour electrical interconnects each of which is arranged to extend perpendicularly to the rows to electrically connect metallization on the rear surfaces of at least one pair of equal voltage solar cells located side-by-side in adjacent super cell rows to provide detour current paths passing through the detour electrical interconnect and through the rear surface metallization of the pair of solar cells around one or more other solar cells in the event that the one or more other solar cells provide insufficient current for normal operation of the module;
wherein the detour current paths do not pass through bypass diodes.

2. The solar module of claim 1 , wherein each detour electrical interconnect has a length shorter than the width of two rows and is conductively bonded at each end to one or the other of a pair of solar cells.

3. The solar module of claim 2 , wherein the detour electrical interconnects are conductively bonded to contact pads on the rear surfaces of the solar cells they interconnect, and the contact pads are positioned adjacent to and elongated parallel to short ends of their solar cells.

4. The solar module of claim 2 , wherein the detour electrical interconnects are arranged in one or more lines perpendicular to the rows.

5. The solar module of claim 4 , wherein each line of detour electrical interconnects spans the width of the module perpendicular to the rows and electrically interconnects all rows.

6. The solar module of claim 1 , wherein each detour electrical interconnect extends perpendicularly to the rows to electrically connect rear surfaces of solar cells in three or more rows.

7. The solar module of claim 6 , wherein each detour electrical interconnect spans the width of the module perpendicular to the rows and electrically interconnects all rows.

8. The solar module of claim 1 , comprising a backing sheet bonded to a rear surface of the module, wherein the detour electrical interconnects are provided by a planar metallization pattern on the backing sheet.

9. The solar module of claim 8 , wherein electrical connections to bypass diodes are provided by the planar metallization pattern on the backing sheet, the bypass diodes arranged to bypass one or more groups of solar cells in the event that one or more solar cells in the one or more groups provide insufficient current for normal operation of the module.

10. The solar module of claim 8 , wherein electrical connections to a junction box are provided by the planar metallization pattern on the backing sheet.

11. The solar module of claim 1 , wherein each solar cell in the module is electrically connected to at least one adjacent row solar cell by a detour electrical interconnect.

12. The solar module of claim 1 , wherein the detour electrical interconnects are arranged to compensate for a predetermined solar module cracking pattern.

13. The solar module of claim 1 , wherein:
each detour electrical interconnect has a length shorter than the width of two rows and is conductively bonded at each end to one or the other of a pair of solar cells; and
each solar cell in the module is electrically connected to at least one adjacent row solar cell by a detour electrical interconnect.

14. The solar module of claim 1 , wherein:
each detour electrical interconnect has a length shorter than the width of two rows and is conductively bonded at each end to one or the other of a pair of solar cells; and
the detour electrical interconnects are arranged to compensate for a predetermined solar module cracking pattern.

15. The solar module of claim 1 , wherein:
each detour electrical interconnect spans the width of the module perpendicular to the rows and electrically interconnects all rows; and
each solar cell in the module is electrically connected to at least one adjacent row solar cell by a detour electrical interconnect.

16. The solar module of claim 1 , wherein:
each detour electrical interconnect spans the width of the module perpendicular to the rows and electrically interconnects all rows; and
the detour electrical interconnects are arranged to compensate for a predetermined solar module cracking pattern.

17. The solar module of claim 1 , comprising a backing sheet bonded to a rear surface of the module, wherein:
the detour electrical interconnects are provided by a planar metallization pattern on the backing sheet; and
each solar cell in the module is electrically connected to at least one adjacent row solar cell by a detour electrical interconnect.

18. The solar module of claim 1 , comprising a backing sheet bonded to a rear surface of the module, wherein:
the detour electrical interconnects are provided by a planar metallization pattern on the backing sheet; and
the detour electrical interconnects are arranged to compensate for a predetermined solar module cracking pattern.

19. The solar module of claim 1 , further comprising bypass diodes arranged to bypass one or more groups of solar cells in the event that one or more solar cells in the one or more groups provide insufficient current for normal operation of the module.

20. The solar module of claim 1 , wherein the detour electrical interconnects are conductively bonded to contact pads on the rear surfaces of the solar cells they interconnect, and the contact pads are positioned adjacent to and elongated parallel to short ends of their solar cells.

21. The solar module of claim 1 , wherein any portions of the detour electrical interconnects that are visible between the rows from a front view of the solar module are covered with a dark coating or otherwise darkened to reduce visible contrast between the detour electrical interconnects and the super cells.

Assignees

• Sunpower Corp

Inventors

• Morad Ratson
• Almogy Gilad
• Lance Tamir
• Beckett Nathan

Classifications

• H02S40/36

  characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection · CPC title

• H02S40/34

  comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes · CPC title

• H02S20/25

  Roof tile elements · CPC title

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• H01L31/0504 Primary

  Electricity · mapped topic