Flexible Modules Using <70 μm Thick Silicon Solar Cells

127907-Thumbnail Image.png
Description

Highly flexible modules using thin 153 cm[superscript 2] silicon crystalline cells and transparent fluoropolymer foil are demonstrated. The modules can be flexed 200 times around a bend radius of 4 cm without change in efficiency. The silicon crystalline heterojunction solar

Highly flexible modules using thin 153 cm[superscript 2] silicon crystalline cells and transparent fluoropolymer foil are demonstrated. The modules can be flexed 200 times around a bend radius of 4 cm without change in efficiency. The silicon crystalline heterojunction solar cells are 65±5 μm-thick with efficiencies up to 18.4%. Cracks in the solar cells and interconnections that are induced by mechanical stress during module bending are examined using electroluminescence. Two interconnection solutions are discussed: ribbons affixed to the busbars using a conductive adhesive, and indium coated wires directly bonded to the cell fingers. Modules using wire interconnection are found to be highly flexible with efficiencies greatly exceeding existing commercial flexible modules using thin films and have potential applications in light-weight modules for building integrated and portable photovoltaic power.

Date Created
2016-09-23
Agent

Wire Interconnections in Solar Modules

135917-Thumbnail Image.png
Description
Wire connected solar cells are a promising new technology that can increase the efficiency and reduce the cost of solar modules. The use of wire rather than ribbon bus bars can lead to reduced shading, better light trapping, and reduced

Wire connected solar cells are a promising new technology that can increase the efficiency and reduce the cost of solar modules. The use of wire rather than ribbon bus bars can lead to reduced shading, better light trapping, and reduced material costs, all while eliminating the need for soldering. This research first analyzes the optimal wire gauge to reduce cracking and improve efficiency. Wire sizes between 20 AWG and 28 AWG were tested, with the optimal size being between 24 AWG and 26 AWG for the ethylene vinyl acetate (EVA) layer used in the module. A polyethylene sheet was then added between the wires and EVA layer to prevent the EVA from running underneath the wires during lamination, ultimately allowing for a more uniform contact and only a slight reduction in quantum efficiency. Then, a comparison between tinned copper wires and indium coated copper wires is shown. A mini-module efficiency of 20.0% has been achieved using tinned copper wires, while indium coated copper wires have produced a mini-module efficiency of 21.2%. Thus, tinned copper wires can be a viable alternative to indium coated copper wires, depending on the needs of the customers and the current price of indium. The module design throughout the research utilizes a planar assembly method, which improves the ease of manufacturing for wire interconnection technology. A two-cell base component is constructed and shown, with the intended future application of making large wire connected modules. Finally, wire applications in both single-cell and four-cell flexible modules are explored, with an efficiency of 18.65% achieved on a single-cell, flexible, heterojunction solar module using wire interconnections. A fully flexible four-cell string is developed, and future recommendations for related research are included.
Date Created
2015-12
Agent