High efficiency configuration for solar cell string

Patent metadata

Field	Value
Publication number	US-11595000-B2
Application number	US-202016900660-A
Country	US
Kind code	B2
Filing date	Jun 12, 2020
Priority date	Nov 8, 2012
Publication date	Feb 28, 2023
Grant date	Feb 28, 2023

Abstract

A high efficiency configuration for a string of solar cells comprises series-connected solar cells arranged in an overlapping shingle pattern. Front and back surface metallization patterns may provide further increases in efficiency.

First claim

What is claimed is:

1. An apparatus comprising:
a first string of solar cells and a second string of solar cells, each string of solar cells comprising rectangular or substantially rectangular solar cells arranged in line with long sides of adjacent solar cells overlapping and conductively bonded to each other with an electrically conductive bonding material to electrically connect the solar cells in series,
an interconnect different from the electrically conductive bonding material, the interconnect located at an end of the first string and electrically connecting the first string of solar cells to the second string of solar cells, the interconnect extending along an entire length of the long sides of the solar cells in the first and second strings of solar cells and interposed between the first and second strings of solar cells, the interconnect comprising a bypass diode tap located at one end of the interconnect and extending past short sides of the solar cells in the first and second strings, the bypass diode tap configured to provide a connection point for a bypass diode, and
the bypass diode electrically connected to the bypass diode tap by a metal ribbon contact, the metal ribbon contact sandwiched between two insulating sheets, the metal ribbon contact comprising a narrow neck and a void space, the narrow neck and the void space configured to make the metal ribbon contact flexible, wherein the bypass diode, metal ribbon contact, and two insulating sheets form a flex circuit wherein the flex circuit is attached to a substrate supporting the first and second strings of solar cells by an adhesive layer.

2. The apparatus of claim 1 , wherein the ratio of the length of a long side of the rectangular or substantially rectangular solar cells to the length of a short side of the rectangular or substantially rectangular solar cells is greater than or equal to three.

3. A solar device comprising:
a first string of rectangular or substantially rectangular crystalline silicon solar cells arranged in line with long sides of adjacent solar cells overlapping and conductively bonded to each other with an electrically conductive bonding material to electrically connect the solar cells in series;
a first end solar cell located at a first end of the first string;
a second end solar cell located at a second end of the first string;
a first electrically conductive interconnect different from the electrically conductive bonding material conductively bonded to the first end solar cell;
a second electrically conductive interconnect different from the electrically conductive bonding material conductively bonded to the second end solar cell,
the first and second interconnects each extending along an entire length of the long sides of the solar cells in the string of solar cells, the first and second interconnects each comprising a bypass diode tap located at one end of the interconnects and extending past short sides of the solar cells in the first string, the bypass diode tap configured to provide a connection point for a bypass diode; and
a bypass diode electrically connected between the first and second interconnects by two metal ribbon contacts, each the metal ribbon contact sandwiched between two insulating sheets, each metal ribbon contact comprising a narrow neck and a void space, the narrow neck and the void space configured to make the metal ribbon contact flexible, wherein the bypass diode, metal ribbon contacts, and two insulating sheets form a flex circuit wherein the flex circuit is attached to a substrate supporting the first string of solar cells by an adhesive layer,
wherein either the first or the second electrically conductive interconnects is electrically connected to a second string of rectangular or substantially rectangular crystalline silicon solar cells and is interposed between the first and second strings of solar cells.

4. The apparatus of claim 1 , wherein
the interconnect comprises a plurality of tabs configured to provide connection points to either the first or second string of solar cells.

5. The apparatus of claim 1 , wherein the interconnect is mechanically compliant.

6. The apparatus of claim 1 , wherein the bypass diode tap is a ribbon that extends laterally to a side of the first string of solar cells to connect to the first bypass diode.

7. The apparatus of claim 1 , wherein:
the first string includes a first end and a second end;
the first string includes a group of solar cells that includes a first solar cell at the first end of the first string and a second solar cell that is between the first and second ends but not at the second end of the first string;
a first conductor that connects to the first solar cell;
a second conductor that connects to the second solar cell;
a second bypass diode that connects between the first and second conductors configured to bypass the group of solar cells within the first string.

8. The apparatus of claim 1 , wherein the metal ribbon contact is formed from solder-coated metal.

9. The apparatus of claim 8 , wherein the metal is copper.

10. The apparatus of claim 1 , wherein the two insulating sheets are formed from polyimide.

11. The apparatus of claim 1 , wherein one of the two insulating sheets comprises an opening configured to expose a region of the metal ribbon contact where the bypass diode is attached.

12. The apparatus of claim 1 , wherein one of the two insulating sheets comprises an opening configured to expose a region of the metal ribbon contact where the metal ribbon contact is connected to the bypass diode tap.

13. The apparatus of claim 1 , wherein the void space of the metal ribbon contact is oval shaped.

14. The apparatus of claim 1 , wherein the bypass diode is attached to a substrate supporting the first and second strings of solar cells.

Assignees

• Sunpower Corp
• Maxeon Solar Pte Ltd

Inventors

• Morad Ratson
• Beckett Nathan
• Gannon John
• Almogy Gilad

Classifications

• H10F71/00

  Manufacture or treatment of devices covered by this subclass (patterning processes to connect thin photovoltaic cells in integrated devices, or assemblies of multiple devices, having photovoltaic cells H10F19/33; manufacture or treatment of encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells H10F19/80; manufacture or treatment of integrated devices, or assemblies of multiple devices, comprising at least one element in which radiation controls the flow of current H10F39/00) · CPC title

• H10F19/00 Primary

  Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules · CPC title

• H10F77/955

  for photovoltaic devices · CPC title

• H10F77/937

  Busbar structures for modules · CPC title

• H10F19/908 Primary

  for back-contact photovoltaic cells · CPC title