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 series connected silicon solar cells grouped into a first super cell comprising a first cut strip having a front side metallization pattern along a first outside edge overlapped by a second cut strip.   
     
     
         2 . An apparatus as in  claim 1  wherein the first cut strip and the second cut strip have a length reproducing a shape of a wafer from which the first cut strip is divided. 
     
     
         3 . An apparatus as in  claim 2  wherein the length is 156 mm. 
     
     
         4 . An apparatus as in  claim 2  wherein the length is 125 mm. 
     
     
         5 . An apparatus as in  claim 2  wherein an aspect ratio between a width of the first cut strip and the length is between about 1:2 to about 1:20. 
     
     
         6 . An apparatus as in  claim 2  wherein the first cut strip includes a first chamfered corner. 
     
     
         7 . An apparatus as in  claim 6  wherein the first chamfered corner is along the first outside edge. 
     
     
         8 . An apparatus as in  claim 6  wherein the first chamfered corner is not along the first outside edge. 
     
     
         9 . An apparatus as in  claim 6  wherein the second cut strip includes a second chamfered corner. 
     
     
         10 . An apparatus as in  claim 9  wherein an overlapping edge of the second cut strip includes the second chamfered corner. 
     
     
         11 . An apparatus as in  claim 9  wherein an overlapping edge of the second cut strip does not include the second chamfered corner. 
     
     
         12 . An apparatus as in  claim 6  wherein the length reproduces a shape of a pseudo-square wafer from which the first cut strip is divided. 
     
     
         13 . An apparatus as in  claim 6  wherein a width of the first cut strip is different from a width of the second cut strip such that the first cut strip and the second cut strip have approximately a same area. 
     
     
         14 . An apparatus as in  claim 1  wherein the second cut strip overlaps the first cut strip by between about 1-5 mm. 
     
     
         15 . An apparatus as in  claim 1  wherein the front side metallization pattern comprises a bus bar. 
     
     
         16 . An apparatus as in  claim 15  wherein bus bar includes a tapered portion. 
     
     
         17 . An apparatus as in  claim 1  wherein the front side metallization pattern comprises a discrete contact pad. 
     
     
         18 . An apparatus as in  claim 17  wherein:
 second cut strip is bonded to the first cut strip by adhesive; and 
 the discrete contact pad further comprises a feature to confine adhesive spreading. 
 
     
     
         19 . An apparatus as in  claim 18  wherein the feature comprises a moat. 
     
     
         20 . An apparatus as in  claim 1  wherein the front side metallization pattern comprises a bypass conductor. 
     
     
         21 . An apparatus as in  claim 1  wherein the front side metallization pattern comprises a finger. 
     
     
         22 . An apparatus as in  claim 1  wherein the first cut strip further comprises a rear side metallization pattern along a second outside edge opposite to the first outside edge. 
     
     
         23 . An apparatus as in  claim 22  wherein the rear side metallization pattern comprises a contact pad. 
     
     
         24 . An apparatus as in  claim 22  wherein the rear side metallization pattern comprises a bus bar. 
     
     
         25 . An apparatus as in  claim 1  wherein the super cell comprises at least nineteen silicon cut strips each having a breakdown voltage greater than about 10 volts. 
     
     
         26 . An apparatus as in  claim 1  wherein the super cell is connected with another super cell on the module front surface. 
     
     
         27 . An apparatus as in  claim 26  wherein the module front surface comprises a white backing featuring darkened stripes corresponding to gaps between the super cell and the other super cell. 
     
     
         28 . An apparatus as in  claim 26  wherein:
 the solar module front surface comprises a backing sheet; and 
 the backing sheet, the interconnect, the super cell, and an encapsulant comprise a laminated structure. 
 
     
     
         29 . An apparatus as in  claim 28  wherein the encapsulant comprises a thermoplastic polymer. 
     
     
         30 . An apparatus as in  claim 29  wherein the thermoplastic polymer comprises a thermoplastic olefin polymer. 
     
     
         31 . An apparatus as in  claim 26  further comprising an interconnect between the super cell and the other super cell. 
     
     
         32 . An apparatus as in  claim 31  wherein a portion of the interconnect is covered by a dark film. 
     
     
         33 . An apparatus as in  claim 31  wherein a portion of the interconnect is colored. 
     
     
         34 . An apparatus as in  claim 31  further comprising a ribbon conductor electrically connecting the super cell to an electrical component. 
     
     
         35 . An apparatus as in  claim 34  wherein the ribbon conductor is conductively bonded to a rear side of the first cut strip. 
     
     
         36 . An apparatus as in  claim 34  wherein the electrical component comprises a bypass diode. 
     
     
         37 . An apparatus as in  claim 34  wherein the electrical component comprises a switch. 
     
     
         38 . An apparatus as in  claim 34  wherein the electrical component comprises a junction box. 
     
     
         39 . An apparatus as in  claim 38  wherein the junction box overlaps and is in mating arrangement with another junction box. 
     
     
         40 . An apparatus as in  claim 26  wherein the super cell and the other super cell are connected in series.