# US 2018/0323333 A1 · Shingled solar cell module

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- Number: US 2018/0323333 A1
- Document ID: US20180323333A1
- Status: Published application
- Kind: A1
- Application number: 16/020,241
- Filed: 2018-06-27
- Published: 2018-11-08
- Earliest claimed: 2014-05-27
- Assignees: SunPower Corporation
- Applicants: Sunpower Corporation
- Inventors: Ratson MORAD; Gilad ALMOGY; Itai SUEZ; Jean HUMMEL; Nathan BECKETT; Yafu LIN; John GANNON; Michael J. STARKEY; Robert STUART; Tamir LANCE; Dan MAYDAN
- Web page: https://patentgrep.com/patent/US20180323333A1

## CPC

- H10F 19/70: comprising bypass diodes (bypass diodes in a junction box H02S40/34)
- H02S 40/32: comprising DC/AC inverter means associated with the PV module itself, e.g. AC modules
- H02S 40/34: comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
- H10F 10/166: the Group IV-IV heterojunctions being heterojunctions of crystalline and amorphous materials, e.g. silicon heterojunction [SHJ] photovoltaic cells
- H10F 19/00: Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
- H10F 19/80: Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
- H10F 19/904: {characterised by the shapes of the structures}
- H10F 71/136: {Singulating, e.g. dicing}
- H10F 71/137: {Batch treatment of the devices}
- H10F 77/147: {Shapes of bodies}
- H10F 77/935: {for photovoltaic devices or modules}
- H10F 77/937: {Busbar structures for modules}
- H02S 20/25: Roof tile elements
- H02S 30/00: Structural details of PV modules other than those related to light conversion (semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H10F10/00, H10F19/00, of organic PV modules H10K30/00)
- H02S 30/10: Frame structures
- H02S 40/30: Electrical components
- H02S 40/36: characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
- H02S 50/00: Monitoring or testing of PV systems, e.g. load balancing or fault identification
- H02S 50/10: Testing of PV devices, e.g. of PV modules or single PV cells (testing of semiconductor devices during manufacturing {H10P74/00})
- H10F 10/14: Photovoltaic cells having only PN homojunction potential barriers
- H10F 19/40: comprising photovoltaic cells in a mechanically stacked configuration
- H10F 19/75: the bypass diodes being integrated or directly associated with the photovoltaic cells, e.g. formed in or on the same substrate
- H10F 19/804: {Materials of encapsulations}
- H10F 19/807: {Double-glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets}
- H10F 19/85: Protective back sheets
- H10F 19/90: Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers (between thin-film photovoltaic cells on a single substrate H10F19/35)
- H10F 19/902: {for series or parallel connection of photovoltaic cells}
- H10F 19/908: {for back-contact photovoltaic cells}
- H10F 71/121: {The active layers comprising only Group IV materials}
- H10F 77/211: {for photovoltaic cells}
- H10F 77/215: {Geometries of grid contacts}
- H10F 77/50: Encapsulations or containers (for photovoltaic modules H10F19/80)
- Y02B 10/10: Photovoltaic [PV]
- Y02E 10/50: Photovoltaic [PV] energy
- Y02E 10/547: Monocrystalline silicon PV cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## 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.

## Claims

### Claim 1

An apparatus comprising:
a series connected string of N rectangular silicon solar cells having on average a breakdown voltage Vc and having on average an open circuit voltage Voc, 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)(Vc) is greater than Vc, 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 2)

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

### Claim 4 (depends on 1)

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.

### Claim 5 (depends on 4)

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

### Claim 6 (depends on 5)

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

### Claim 7 (depends on 4)

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

### Claim 8 (depends on 1)

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.

### Claim 9 (depends on 1)

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.

### Claim 10 (depends on 1)

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

### Claim 11 (depends on 1)

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

### Claim 12 (depends on 11)

The apparatus of claim 11, wherein Vc is less than about 20 volts.

### Claim 13 (depends on 11)

The apparatus of claim 11, wherein Vc is less than about 15 volts.

### Claim 14 (depends on 1)

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

### Claim 15 (depends on 14)

The apparatus of claim 14, wherein Vc is about 16 volts to about 30 volts

### Claim 16 (depends on 14)

The apparatus of claim 14, wherein Vc is less than about 30 volts.

### Claim 17 (depends on 14)

The apparatus of claim 14, wherein Vc is less than about 25 volts.

### Claim 18 (depends on 14)

The apparatus of claim 14, wherein Vc is less than about 20 volts.

### Claim 19 (depends on 14)

The apparatus of claim 14, wherein Vc is less than about 15 volts.

### Claim 20 (depends on 1)

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

### Claim 21 (depends on 22)

The apparatus of claim 22, Vc is greater than about 10 volts.

### Claim 22 (depends on 22)

The apparatus of claim 22, Vc is less than about 35 volts.

### Claim 23 (depends on 22)

The apparatus of claim 22, wherein Vc is about 16 volts to about 30 volts

### Claim 24 (depends on 22)

The apparatus of claim 22, wherein Vc is less than about 30 volts.

### Claim 25 (depends on 22)

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

### Claim 26 (depends on 22)

The apparatus of claim 22, wherein Vc is less than about 20 volts.

### Claim 27 (depends on 22)

The apparatus of claim 22, wherein Vc is less than about 15 volts.

### Claim 28 (depends on 1)

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

### Claim 29

An apparatus comprising:
means for spreading heat generated by a hotspot condition of one or more rectangular silicon solar cells of a series connected string of N rectangular silicon solar cells having on average a breakdown voltage Vc and having on average an open circuit voltage Voc, 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, such that heat from the one or more rectangular silicon solar cells having the hotspot condition is spread to one or more other rectangular silicon solar cells of the first super cell to prevent irreversible damage to the apparatus from the hotspot condition, wherein
the product (N−1)(Voc) is greater than Vc, 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.