SHINGLED SOLAR CELL MODULE
A high efficiency configuration for a solar cell module comprises solar cells arranged 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.
1 . An apparatus comprising:
a solar module comprising a front surface including a first series connected string of at least nineteen solar cells each having a breakdown voltage greater than about 10V, and grouped into a super cell comprising a first silicon solar cell arranged with an end overlapping and conductively bonded with an adhesive to a second silicon solar cell; and
an interconnect conductively bonded to a solar cell surface.
2 . An apparatus as in claim 1 wherein the solar cell surface comprises a back of the first silicon solar cell.
3 . An apparatus as in claim 2 further comprising a ribbon conductor electrically connecting the super cell to an electrical component.
4 . An apparatus as in claim 3 wherein the ribbon conductor is conductively bonded to the solar cell surface away from the overlapping end.
5 . An apparatus as in claim 4 wherein the electrical component is on a solar module rear surface.
6 . An apparatus as in claim 4 wherein the electrical component comprises a junction box.
7 . An apparatus as in claim 6 wherein the junction box is in mating engagement with another junction box on a different module overlapped by the module.
8 . An apparatus as in claim 4 wherein the electrical component comprises a bypass diode.
9 . An apparatus as in claim 4 wherein the electrical component comprises a module terminal.
10 . An apparatus as in claim 4 wherein the electrical component comprises an inverter.
11 . An apparatus as in claim 10 wherein the inverter comprises a DC/AC micro-inverter.
12 . An apparatus as in claim 11 wherein the DC/AC micro-inverter is on a solar module rear surface.
13 . An apparatus as in claim 4 wherein the electrical component comprises a power management device.
14 . An apparatus as in claim 13 wherein the power management device comprises a switch.
15 . An apparatus as in claim 14 further comprising a voltage sensing controller in communication with the switch.
16 . An apparatus as in claim 13 wherein the power management device is configured to,
receive a voltage output of the super cell;
based upon the voltage, determine if a solar cell of the super cell is in reverse bias; and
disconnect the solar cell in reverse bias from a super cell module circuit.
17 . An apparatus as in claim 16 wherein the power management device is in electrical communication with a central inverter.
18 . An apparatus as in claim 13 wherein the power management device comprises a DC/DC module power optimizer.
19 . An apparatus as in claim 3 wherein the interconnect is sandwiched between the super cell and another super cell on the front surface.
20 . An apparatus as in claim 3 wherein the ribbon conductor is conductively bonded to the interconnect.
21 . An apparatus as in claim 3 wherein the interconnect provides a resistance to current flow of less than or equal to about 0.012 Ohms.
22 . An apparatus as in claim 3 wherein the interconnect is configured to accommodate differential expansion between the first silicon solar cell and the interconnect for a temperature range of between about −40° C. to about 85° C.
23 . An apparatus as in claim 3 wherein a thickness of the interconnect is less than or equal to about 100 microns.
24 . An apparatus as in claim 3 wherein a thickness of the interconnect is less than or equal to about 30 microns.
25 . An apparatus as in claim 3 wherein the super cell has a length in a direction of current flow of at least about 500 mm.
26 . An apparatus as in claim 3 further comprising an other super cell on the module front surface.
27 . An apparatus as in claim 26 wherein the interconnect connects the other super cell in series with the super cell.
28 . An apparatus as in claim 26 wherein the interconnect connects the other super cell in parallel with the super cell.
29 . An apparatus as in claim 26 wherein the front surface comprises a white backing featuring darkened stripes of location and width corresponding to gaps between the super cell and the other super cell.
30 . An apparatus as in claim 3 wherein the interconnect comprises a pattern.
31 . An apparatus as in claim 30 wherein the pattern comprises slits, slots, and/or holes.
32 . An apparatus as in claim 3 wherein a portion of the interconnect is dark.
33 . An apparatus as in claim 3 wherein:
the first silicon solar cell includes chamfered corners;
the second silicon solar cell lacks chamfered corners; and
each silicon solar cell of the super cell has substantially a same front surface area exposed to light.
34 . An apparatus as in claim 3 wherein:
the first silicon solar cell includes chamfered corners;
the second silicon solar cell includes chamfered corners; and
the side comprises a long side overlapping a long side of the second silicon solar cell.
35 . An apparatus as in claim 3 wherein the interconnect forms a bus.
36 . An apparatus as in claim 3 wherein the interconnect is conductively bonded to the solar cell surface at a glued joint.
37 . An apparatus as in claim 3 wherein a first portion of the interconnect folds around an edge of the super cell such that a remaining second portion is located on a backside of the super cell.
38 . An apparatus as in claim 3 further comprising a metallization pattern on the front surface and comprising a line running along a long side, the apparatus further comprising at plurality of discrete contact pads located between the line and the long side.
39 . An apparatus as in claim 38 wherein:
the metallization further comprises fingers electrically connected to respective discrete contact pads and running perpendicularly to the long side; and
the conductive line interconnects the fingers.
40 . An apparatus as in claim 38 wherein the metallization pattern comprises a raised feature to confine spreading of the adhesive.