Patent Application
20160226439
The present invention is directed to photovoltaic systems and manufacturing processes and apparatus thereof. In particular, the present invention provides an apparatus and method for using diode protection for a high-density solar module.
As the population of the world has increased, industrial expansion has led to a corresponding increased consumption of energy. Energy often comes from fossil fuels, including coal and oil, hydroelectric plants, nuclear sources, and others. As merely an example, the International Energy Agency projects further increases in oil consumption, with developing nations such as China and India accounting for most of the increase. Almost every element of our daily lives depends, in part, on oil, which is becoming increasingly scarce. As time further progresses, an era of “cheap” and plentiful oil is coming to an end. Accordingly, other and alternative sources of energy have been developed.
In addition to oil, we have also relied upon other very useful sources of energy such as hydroelectric, nuclear, and the like to provide our electricity needs. As an example, most of our conventional electricity requirements for home and business use comes from turbines run on coal or other forms of fossil fuel, nuclear power generation plants, and hydroelectric plants, as well as other forms of renewable energy. Often times, home and business use of electrical power has been stable and widespread.
Most importantly, much if not all of the useful energy found on the Earth comes from our sun. Generally all common plant life on the Earth achieves life using photosynthesis processes from sunlight. Fossil fuels such as oil were also developed from biological materials derived from energy associated with the sun. For human beings including “sun worshipers,” sunlight has been essential. For life on the planet Earth, the sun has been our most important energy source and fuel for modern day solar energy.
Solar energy possesses many desirable characteristics; it is renewable, clean, abundant, and often widespread. Certain technologies developed often capture solar energy, concentrate it, store it, and convert it into other useful forms of energy.
Solar panels have been developed to convert sunlight into energy. For example, solar thermal panels are used to convert electromagnetic radiation from the sun into thermal energy for heating homes, running certain industrial processes, or driving high-grade turbines to generate electricity. As another example, solar photovoltaic panels are used to convert sunlight directly into electricity for a variety of applications. Solar panels are generally composed of an array of solar cells, which are interconnected to each other. The cells are often arranged in series and/or parallel groups of cells in series. Accordingly, solar panels have great potential to benefit our nation, security, and human users. They can even diversify our energy requirements and reduce the world's dependence on oil and other potentially detrimental sources of energy.
Although solar panels have been used successfully for certain applications, there are still certain limitations. Solar cells are often costly. Depending upon the geographic region, there are often financial subsidies from governmental entities for purchasing solar panels, which often cannot compete with the direct purchase of electricity from public power companies. Additionally, the panels are often composed of costly photovoltaic silicon bearing wafer materials, which are often difficult to manufacture efficiently on a large scale, and sources can be limited.
Therefore, it is desirable to have novel system and method for manufacturing solar panels.
The present invention is directed to photovoltaic systems and manufacturing processes and apparatus thereof. In particular, the present invention provides an apparatus and method for using diode protection for a high-density solar module. There are other embodiments as well.
In an example, a solar module apparatus is provided. The apparatus has a plurality of strings, each of the plurality of strings being configured in a parallel electrical arrangement with each other and a plurality of photovoltaic strips forming each of the plurality of photovoltaic strings. The apparatus has a first end termination configured along a first end of each of the plurality of strings and a second end termination configured along a second end of each of the plurality of strings. The module has an equivalent diode device configured between the first end termination and the second end termination such that one of the plurality of photovoltaic strips associated with one of the plurality of strings when shaded causes the plurality of strips (“Shaded Strips”) associated with the one of the strings to cease generating electrical current from application of electromagnetic radiation, while a remaining plurality of strips, associated with the remaining plurality of strings, each of which generates a current that is substantially equivalent as an electrical current while the Shaded Strips are not shaded, and the equivalent diode device between the first terminal and the second terminal for the plurality of strips is configured to turn-on to by-pass electrical current through the equivalent diode device such that the electrical current that was by-passed traverses the equivalent diode device coupled to the plurality of strips that are configured parallel to each other.
Many benefits can be achieved by ways of the present invention. As an example, the present module can be made using conventional process and materials. Additionally, the present module is more efficient than conventional module designs. Furthermore, the present module, and related techniques provides for a more efficient module usage using by-pass diodes configured with multiple zones of solar cells. Depending upon the example, there are other benefits as well.
A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.
The present invention is directed to photovoltaic systems and manufacturing processes and apparatus thereof. There are other embodiments as well.
Embodiments of the present invention provide system and methods for manufacturing high density solar panels. Embodiments of the present invention use overlapped or tiled photovoltaic strip elements to increase the amount of photovoltaic material, thereby increasing an amount of power, while reducing an amount of series resistance losses in the solar panel. It is noted that specific embodiments are shown for illustrative purposes, and represent examples. One skilled in the art would recognize other variations, modifications, and alternatives.
Although orientation is not a part of the invention, it is convenient to recognize that a solar module has a side that faces the sun when the module is in use, and an opposite side that faces away from the sun. Although, the module can exist in any orientation, it is convenient to refer to an orientation where “upper” or “top” refer to the sun-facing side and “lower” or “bottom” refer to the opposite side. Thus an element that is said to overlie another element will be closer to the “upper” side than the element it overlies.
While the above is a complete description of specific embodiments of the invention, the above description should not be taken as limiting the scope of the invention as defined by the claims.
In an example, a solar module is shown. The module has an array of solar cells. The array can be N by M, where N is an integer of 1 and greater and M is an integer of 2 and greater. In an example, the module has a plurality of zones dividing the array of solar cells. In an example, the zones are numbered from 1 through R, where R is 4 and greater. Each of the plurality of zones is in series with each other in an example. As shown, the solar module has three zones each of which is connected to each other in series.
As shown, the module has a plurality of photovoltaic strings dividing each of the plurality of zones. Each of the plurality of photovoltaic strings is in parallel with each other. In an example, the plurality of photovoltaic strings are numbered, respectively, from 2 to 12. As shown in this example, each zone has six strings, which are coupled to each other.
As shown, the module has a plurality of photovoltaic strips forming each of the plurality of photovoltaic strings. As shown, the plurality of strips range in number from 2 to 30. Each of the plurality of strips is configured in a series arrangement with each other.
As also shown, a first bus bar and a second bus bar are configured on each of the zones of the solar cells. In this example, four (4) bus bars are illustrated. A first and second bus bar are configured to the first zone. The second and a third bus bar are configured to a second zone. The third and a four bus bar are configured to the third zone. As used herein, the terms “first” “second” “third” or “fourth” do not necessarily imply order, and should be interpreted under ordinary meaning. In an example, an equivalent diode device is configured between the first bus bar and the second bus bar for a particular zone. Each zone has an equivalent diode device, as shown.
As shown, one of the plurality of photovoltaic strips associated with one of the plurality of strings and associated with a first plurality of zones is shaded. The one shaded strip causes the plurality of strips (“Shaded Strips”) associated with the one of the strings to cease generating electrical current from application of electromagnetic radiation associated one of the strings. All of the remaining plurality of strips, associated with the remaining plurality of strings in the zone, each of which generates a current that is substantially equivalent as the current while the Shaded Strips are not shaded. The diode device between the first bus bar and the second bus bar for the plurality of strips is configured to turn-on to by-pass electrical current from the Shaded Strips through the diode device and the electrical current that was by-passed traverses an equivalent diode device coupled to the plurality of strips associated with a second plurality of zones.
As shown, six of the plurality of photovoltaic strips associated with one of the plurality of strings and associated with a first plurality of zones is shaded. The shaded strips causes the plurality of strips (“Shaded Strips”) associated with the one of the strings to cease generating electrical current from application of electromagnetic radiation associated one of the strings. All of the remaining plurality of strips, associated with the remaining plurality of strings in the zone, each of which generates a current that is substantially equivalent as the current while the Shaded Strips are not shaded. The diode device between the first bus bar and the second bus bar for the plurality of strips is configured to turn-on to by-pass electrical current from the Shaded Strips through the diode device and the electrical current that was by-passed traverses an equivalent diode device coupled to the plurality of strips associated with a second plurality of zones.
In an example, the plurality of strings can be numbered from 2 to 12, while six is shown in this illustration. Each of the plurality of strings is configured in a parallel electrical arrangement with each other. In an example, the plurality of photovoltaic strips forms each of the plurality of photovoltaic strings. The plurality of strips can range from 2 to 30 such that each of the plurality of strips is configured in a series arrangement with each other. In an example, the zone has a first end termination configured along a first end of each of the plurality of strings. In an example, the first end termination is a first terminal. In an example, the second end termination is configured along a second end of each of the plurality of strings. In an example, the second end termination is a second terminal.
In an example, an equivalent diode device is configured between the first end termination and the second end termination such that one of the plurality of photovoltaic strips associated with one of the plurality of strings when shaded causes the plurality of strips (“Shaded Strips”) associated with the one of the strings to cease generating electrical current from application of electromagnetic radiation. All of the remaining plurality of strips, associated with the remaining plurality of strings, each of which generates a current that is substantially equivalent as an electrical current while the Shaded Strips are not shaded. The equivalent diode device between the first terminal and the second terminal for the plurality of strips is configured to turn-on to by-pass electrical current through the equivalent diode device such that the electrical current that was by-passed traverses the equivalent diode device coupled to the plurality of strips that are configured parallel to each other. In an example, the plurality of strings is provided in a zone. As previously noted, one zone is among a plurality of zones to form the solar module.
In an example, the solar module is configured to generate from 100 to 600 Watts. Also, the equivalent diode characterized as a plurality of individual diode devices each of which protects a string among the plurality of strings. Of course, there can also be other variations, alternatives, and modifications.
In an example, the equivalent diode device is a sum of individual diode devices coupled to each of the plurality of strips in each of the plurality of strings in each zone.
In an example, each of the plurality of strips comprises a thickness of photovoltaic material comprising a front bus bar and a back bus bar. In an example, the front bus bar is provided along a first edge region and the back bus bar being provided along a second edge region.
In an example, each of the plurality of strips comprises a thickness of photovoltaic material comprising a front bus bar and a back bus bar. In an example, the front bus bar is provided along a first edge region and the back bus bar being provided along a second edge region. In an example, each of the plurality of strips is associated with one of the plurality of strings. In an example, each of the plurality of strings is associated with one of the plurality of strings being in an overlapped configuration to physically and electrically configure the string.
In an example, each of the plurality of strips comprises a thickness of photovoltaic material comprising a front bus bar and a back bus bar. In an example, the front bus bar is provided along a first edge region and the back bus bar being provided along a second edge region. In an example, each of the plurality of strips is associated with one of the plurality of strings. In an example, each of the plurality of strings associated with one of the plurality of strings being in an overlapped configuration to physically and electrically configured to the string. In an example, each of the plurality of strips is configured from a silicon based mono-crystalline or multi-crystalline solar cell.
In an example, the array of solar cells configured to generate 300 to 450 Watts. In an example, each of the zones is configured to generate at least 70 Watts. In an example, each of the strips is configured to generate at least 0.8 Watt.
In an example, the module further comprising a pair of substrate members configured to sandwich the array of solar cells, at least one of the substrate members being a transparent material. In an example, the array of solar cells is operable at a maximum power of the array of solar cells minus a power amount associated with the Shaded Strips.
In an example, the module further comprising a power output equivalent to a maximum power rating less an amount equivalent to the string associated with the Shaded Strips. In an example, the module further comprising a power output equivalent to a maximum power rating less an amount equivalent to more the one of the strings associated with the Shaded Strips. In an example, the module further comprising a plurality of electrical strings, each of the electrical stings being configured to form an equivalent strip provided by a plurality of strips from a plurality of stings connected in parallel to each other.
Further details of a tiled or shingled photovoltaic strip arrangement can be found in U.S. Design application No. 29/509,179, filed Nov. 14, 2014, titled “TILED SOLAR CELL DESIGN,” (Our File No.: A906RO-018000US), commonly owned, and hereby incorporated by reference herein. Each of the strips is configured as a rectangular shape free from any visible and separate bus-bars. Of course there can be variations.
In an example, the solar apparatus is configured as parallel array of photovoltaic strips. The apparatus has a first array of photovoltaic strips. In an example, the first array is defined by one photovoltaic strip by n strips. In an example, the plurality of photovoltaic strips are arranged in series in an edge connected configuration and configured in tiled manner and/or layered manner and/or off-set stacked manner. In an example, the apparatus has a second array of photovoltaic strips. The second array is defined by one photovoltaic strip by n strips. In an example, the plurality of photovoltaic strips are arranged in series in an edge connected configuration and configured in a tiled manner and/or layered manner and/or off-set stacked manner. The apparatus has a first electrode member coupling a positive contact region of each of the first array of photovoltaic strips and the second array of photovoltaic strips and a second electrode member coupling a negative contact region of each of the first array of photovoltaic strips and the second array of photovoltaic strips. The apparatus has a diode device configured to the first electrode member and the second electrode member. The first array and the second array are configured to form a parallel string of photovoltaic strips.
In an example, the apparatus has a third array of photovoltaic strips. The third array is defined by one photovoltaic strip by n strips. In an example, the plurality of photovoltaic strips are arranged in series in an edge connected configuration; and a fourth array of photovoltaic strips. The fourth array is defined by one photovoltaic strip by n strips. In an example, the plurality of photovoltaic strips are arranged in series in an edge connected configuration. The first electrode member coupling a positive contact region of each of the third array of photovoltaic strips and the fourth array of photovoltaic strips; and the second electrode member coupling a negative contact region of each of the third array of photovoltaic strips and the fourth array of photovoltaic strips. The first array, the second array, the third array, and the fourth array are configured to form a parallel string of photovoltaic strips.
In an example, each of the photovoltaic strips comprises a width, a length, and a thickness, each of the photovoltaic strips comprising a first contact region and a second contact region. Each of the strips is configured on opposite edges of each other. The first contact region is along a top side of a first edge and the second contact region is along a bottom side of a second edge, which is on the opposite spatial side of the first edge. In an example, the first contact region comprises a first side region having an aluminum bus bar member, while an opposite has no aluminum material.
In an example, the equivalent diode device can be Schottky Barrier Rectifiers By-Pass Diode, or others. The device can have a 20SQ040, “Bypass Diodes for Solar Modules—Schottky Barrier Rectifiers Bypass,” manufactured by Dioden, Lite-on Semiconductor Corp, or others. In an example, the equivalent diode device is a metal of silicon rectifier, majority carrier conduction, has a guard ring for transient protection, low power loss, high efficiency, high surge and current capability, low VF, among other features. The diode is configured to a JEDEC R-6 molded plastic. The diode has a low forward voltage drop of 0.4V to 0.6V, and a maximum DC blocking voltage of 40-45V. Other features are included in a data sheet of such diode by either Lite-on Semiconductor Corp, or others, which are incorporated by reference herein.
It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
