Shingled solar cell module

Patent metadata

Field	Value
Publication number	US-11038072-B2
Application number	US-201816020241-A
Country	US
Kind code	B2
Filing date	Jun 27, 2018
Priority date	May 27, 2014
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

A high efficiency configuration for a solar cell module comprises solar cells conductively bonded to each other in a shingled manner to form super cells, which may be arranged to efficiently use the area of the solar module, reduce series resistance, and increase module efficiency.

First claim

What is claimed is:

1. An apparatus comprising:
a series connected string of N rectangular silicon solar cells connected in parallel with a bypass diode, the solar cells having on average a breakdown voltage V c and having on average an open circuit voltage V oc , the solar cells arranged in line with long sides of adjacent solar cells overlapping and conductively bonded to each other with an electrically and thermally conductive adhesive to form a first super cell, wherein
the product (N−1)(V oc ) is greater than V c , and
no single solar cell or group of <N solar cells in the string of solar cells is individually electrically and directly connected in parallel with a bypass diode.

2. The apparatus of claim 1 , wherein the adhesive has a thickness less than or equal to about 0.1 mm and a thermal conductivity greater than or equal to about 1.5 w/m/k.

3. The apparatus of claim 2 , wherein the adhesive has a thickness less than or equal to about 50 microns.

4. The apparatus of claim 1 , comprising:
another string of series connected rectangular silicon solar cells arranged in line with long sides of adjacent solar cells overlapping and conductively bonded to each other with an electrically and thermally conductive adhesive to form a second super cell;
a first contact pad located on a back surface of a first solar cell in the first super cell;
a second contact pad located on a back surface of a second solar cell in the second super cell; and
an electrical interconnect conductively bonded to the first contact pad and to the second contact pad to electrically connect the first solar cell and the second solar cell.

5. The apparatus of claim 4 , wherein the first solar cell is located at an intermediate position along the first super cell.

6. The apparatus of claim 5 , wherein the second solar cell is located at an intermediate position along second super cell.

7. The apparatus of claim 4 , wherein the interconnect does not conduct current if all solar cells in the apparatus are operating normally.

8. The apparatus of claim 1 , wherein:
a first one of the rectangular silicon solar cells comprises opposing first and second long edges, opposing first and second short edges, a first chamfered corner provided between the first short edge and the second long edge, and a second chamfered corner provided between the second short edge and the second lone edge, where the second long edge is shorter than the first long edge;
a second one of the rectangular silicon solar cells comprises opposing first and second long edges, opposing first and second short edges, a first chamfered corner provided between the first short edge and the first long edge, and a second chamfered corner provided between the second short edge and the first long edge, where the first long edge is shorter than the second long edge; and
the second long edge of the first rectangular silicon solar cell overlaps with and is conductively bonded to the first long edge of the second rectangular silicon solar cell with the electrically and thermally conductive adhesive.

9. The apparatus of claim 1 , wherein:
a first one of the rectangular silicon solar cells comprises opposing first and second long edges, opposing first and second short edges, a first chamfered corner provided between the first short edge and the second long edge, and a second chamfered corner provided between the second short edge and the second lone edge, where the second long edge is shorter than the first long edge;
a second one of the rectangular silicon solar cells comprises opposing first and second long edges, opposing first and second short edges, a first chamfered corner provided between the first short edge and the first long edge, and a second chamfered corner provided between the second short edge and the first long edge, where the first long edge is shorter than the second long edge; and
the first long edge of the first rectangular silicon solar cell overlaps with and is conductively bonded to the second long edge of the second rectangular silicon solar cell with the electrically and thermally conductive adhesive.

10. The apparatus of claim 1 , wherein N is greater than or equal to 30 and V c is less than about 15 volts.

11. The apparatus of claim 1 , wherein N is greater than or equal to 50 and V c is less than about 25 volts.

12. The apparatus of claim 11 , wherein V c is less than about 20 volts.

13. The apparatus of claim 11 , wherein V c is less than about 15 volts.

14. The apparatus of claim 1 , wherein N is greater than or equal to 70 and V c is less than about 35 volts.

15. The apparatus of claim 14 , wherein V c is about 16 volts to about 30 volts.

16. The apparatus of claim 14 , wherein V c is less than about 30 volts.

17. The apparatus of claim 14 , wherein V c is less than about 25 volts.

18. The apparatus of claim 14 , wherein V c is less than about 20 volts.

19. The apparatus of claim 14 , wherein V c is less than about 15 volts.

20. The apparatus of claim 1 , wherein N is greater than or equal to 100 and V c is less than about 50 volts.

21. The apparatus of claim 1 , V c is greater than about 10 volts.

22. The apparatus of claim 1 , V c is less than about 35 volts.

23. The apparatus of claim 22 , wherein V c is about 16 volts to about 30 volts.

24. The apparatus of claim 22 , wherein V c is less than about 30 volts.

25. The apparatus of claim 22 , wherein V c is less than about 25 volts.

26. The apparatus of claim 22 , wherein V c is less than about 20 volts.

27. The apparatus of claim 22 , wherein V c is less than about 15 volts.

28. The apparatus of claim 1 , wherein the string of N rectangular silicon solar cells is encapsulated in a thermoplastic olefin polymer.

Assignees

• Sunpower Corp

Inventors

• Morad Ratson
• Almogy Gilad
• Suez Itai
• Hummel Jean
• Beckett Nathan
• Lin Yafu
• Gannon John
• Starkey Michael J
• Stuart Robert
• Lance Tamir
• Maydan Dan

Classifications

• H10F77/215

  Geometries of grid contacts · CPC title

• H10F77/211

  for photovoltaic cells · CPC title

• H10F77/50

  Encapsulations or containers (for photovoltaic modules H10F19/80) · CPC title

• H10F71/121

  The active layers comprising only Group IV materials · CPC title

• H10F19/908

  for back-contact photovoltaic cells · CPC title