Shingled solar cell module

Abstract

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.

What is claimed is: 
     
         1 . An apparatus comprising:
 a solar module comprising a front surface including a first series connected string of at least 19 solar cells grouped into a first super cell arranged with long sides of adjacent solar cells overlapping and conductively bonded with an adhesive; and   a ribbon conductor electrically connected to a rear surface contact of the first super cell to provide a hidden tap to an electrical component.   
     
     
         2 . An apparatus as in  claim 1  wherein the electrical component comprises a bypass diode. 
     
     
         3 . An apparatus as in  claim 2  wherein the bypass diode is located on a rear surface of the solar module. 
     
     
         4 . An apparatus as in  claim 3  wherein the bypass diode is located outside of a junction box. 
     
     
         5 . An apparatus as in  claim 4  wherein the junction box comprises a single terminal. 
     
     
         6 . An apparatus as in  claim 3  wherein the bypass diode is positioned near an edge of the solar module. 
     
     
         7 . An apparatus as in  claim 2  wherein bypass diode is positioned in a laminate structure. 
     
     
         8 . An apparatus as in  claim 7  wherein the first super cell is encapsulated within the laminate structure. 
     
     
         9 . An apparatus as in  claim 2  wherein the bypass diode is positioned around a perimeter of the solar module. 
     
     
         10 . An apparatus as in  claim 1  wherein the electrical component comprises a module terminal, a junction box, a power management system, a smart switch, a relay, a voltage sensing controller, a central inverter, a DC/AC micro-inverter, or a DC/DC module power optimizer. 
     
     
         11 . An apparatus as in  claim 1  wherein the electrical component is located on a rear surface of the solar module. 
     
     
         12 . An apparatus as in  claim 1  wherein the solar module further comprises a second series connected string of at least 19 solar cells grouped into a second super cell having a first end electrically connected in series to the first super cell. 
     
     
         13 . An apparatus as in  claim 12  wherein the second super cell is overlapping and electrically connected in series to the first super cell with conductive adhesive. 
     
     
         14 . An apparatus as in  claim 12  wherein the rear surface contact is located away from the first end. 
     
     
         15 . An apparatus as in  claim 12  further comprising a flexible interconnect between the first end and the first super cell. 
     
     
         16 . An apparatus as in  claim 15  wherein the flexible interconnect extends beyond side edges of the first and second super cells to electrically connect the first and second super cells in parallel with another super cell. 
     
     
         17 . An apparatus as in  claim 1  wherein the adhesive has a thickness less than or equal to about 0.1 mm, and has a thermal conductivity greater than or equal to about 1.5 w/m/k. 
     
     
         18 . An apparatus as in  claim 1  wherein the solar cells are silicon solar cells having a breakdown voltage greater than about 10V. 
     
     
         19 . An apparatus as in  claim 1  wherein the first super cell has a length in a direction of current flow of at least about 500 mm. 
     
     
         20 . An apparatus as in  claim 1  wherein a solar cell of the first super cell comprises a feature configured to confine spreading of the adhesive. 
     
     
         21 . An apparatus as in  claim 20  wherein the feature comprises a raised feature. 
     
     
         22 . An apparatus as in  claim 21  wherein the feature comprises metallization. 
     
     
         23 . An apparatus as in  claim 22  wherein the metallization comprises a conductive line running a full length of the first long side, the apparatus further comprising at least one contact pad located between the line and the first long side. 
     
     
         24 . An apparatus as in  claim 23  wherein:
 the metallization further comprises fingers electrically connected to the at least one contact pad and running perpendicularly to the first long side; and 
 the conductive line interconnects the fingers. 
 
     
     
         25 . An apparatus as in  claim 20  wherein the feature is on a front side of the solar cell. 
     
     
         26 . An apparatus as in  claim 20  wherein the feature is on a back side of the solar cell. 
     
     
         27 . An apparatus as in  claim 20  wherein the feature comprises a recessed feature. 
     
     
         28 . An apparatus as in  claim 20  wherein the feature is hidden by an adjacent solar cell of the first super cell. 
     
     
         29 . An apparatus as in  claim 1  wherein a solar cell of the first super cell comprises a chamfered portion. 
     
     
         30 . An apparatus as in  claim 29  wherein the first super cell further comprises another solar cell having a chamfered portion, and wherein a long side of the solar cell is in electrical contact with a long side of the other solar cell that has a similar length. 
     
     
         31 . An apparatus as in  claim 29  wherein the first super cell further comprises another solar cell lacking chamfered corners, and the solar cell and the other solar cell have a same area exposed to light. 
     
     
         32 . An apparatus as in  claim 1  wherein:
 the first super cell is arranged with a second super cell in parallel rows on a backing sheet front surface; and 
 the backing sheet is white and comprises darkened stripes of location and width corresponding to gaps between the first super cell and the second super cell. 
 
     
     
         33 . An apparatus as in  claim 1  wherein the first super cell comprises at least one pair of cell strings connected to a power management system. 
     
     
         34 . An apparatus as in  claim 1  further comprising a power management device in electrical communication with the first super cell and configured to,
 receive a voltage output of the first super cell; 
 based upon the voltage, determine if a solar cell of the first super cell is in reverse bias; and 
 disconnect the solar cell in reverse bias from a super cell module circuit. 
 
     
     
         35 . An apparatus as in  claim 34  wherein the power management device comprises a relay. 
     
     
         36 . An apparatus as in  claim 1  wherein the first super cell is disposed on a first backing to form the module having a top conductive ribbon on first side facing a direction of solar energy, the apparatus further comprising:
 another super cell disposed on a second backing to form a different module having a bottom ribbon on a second side facing a direction away from the direction of the solar energy, 
 wherein the different module overlaps and is bonded to a portion of the module including the top ribbon. 
 
     
     
         37 . An apparatus as in  claim 36  wherein the different module is bonded to the module by adhesive. 
     
     
         38 . An apparatus as in  claim 36  wherein the different module is bonded to the module by a mating arrangement. 
     
     
         39 . An apparatus as in  claim 36  further comprising a junction box overlapped by the different module. 
     
     
         40 . An apparatus as in  claim 39  wherein the different module is bonded to the module by a mating arrangement between the junction box and another junction box on a different solar module.