U.S. patent application number 12/470351 was filed with the patent office on 2010-07-29 for connection systems and methods for solar cells.
Invention is credited to Stephen Joseph Gaul.
Application Number | 20100186795 12/470351 |
Document ID | / |
Family ID | 42353165 |
Filed Date | 2010-07-29 |
United States Patent
Application |
20100186795 |
Kind Code |
A1 |
Gaul; Stephen Joseph |
July 29, 2010 |
CONNECTION SYSTEMS AND METHODS FOR SOLAR CELLS
Abstract
Exemplary embodiments provide a solar cell device, and method
for forming the solar cell device by integrating a switch component
into a solar cell element. The solar cell element can include a
solar cell, a solar cell array and/or a solar cell panel. The
integrated solar cell element can be used for a solar sensor, while
the solar sensor can also use discrete switches for each solar cell
area of the sensor. Exemplary embodiments also provide a connection
system for the solar cell elements and a method for
super-connecting the solar cell elements to provide a desired
connection path or a desired power output through switch settings.
The disclosed connection systems and methods can allow for
by-passing underperforming solar cell elements from a plurality of
solar cell elements. In embodiments, the solar cell element can be
extended to include a battery or a capacitor.
Inventors: |
Gaul; Stephen Joseph;
(Melbourne Village, FL) |
Correspondence
Address: |
MH2 TECHNOLOGY LAW GROUP, LLP
1951 KIDWELL DRIVE, SUITE 550
TYSONS CORNER
VA
22182
US
|
Family ID: |
42353165 |
Appl. No.: |
12/470351 |
Filed: |
May 21, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61147888 |
Jan 28, 2009 |
|
|
|
Current U.S.
Class: |
136/244 |
Current CPC
Class: |
H02S 50/00 20130101;
H02S 40/34 20141201; H01L 31/0504 20130101; H01L 29/7804 20130101;
H02S 40/36 20141201; H02S 50/10 20141201; H02S 10/00 20130101; Y02E
10/50 20130101; H01L 31/02 20130101; H01L 27/1421 20130101; H01L
31/02008 20130101; H01L 31/18 20130101; H01L 31/02021 20130101;
H01L 31/112 20130101 |
Class at
Publication: |
136/244 |
International
Class: |
H01L 31/042 20060101
H01L031/042 |
Claims
1. A solar cell connection system comprising: a plurality of switch
components, wherein each switch component comprises at least one
switch; and a plurality of solar cell elements, wherein at least
one solar cell element is associated with one or more adjacent
switches of the plurality of switch components to form a super
connection with one or more adjacent solar cell elements, wherein
each associated switch is set to support a connection arrangement
of the plurality of solar cell elements for a controlled power
output.
2. The system of claim 1, wherein each solar cell element comprises
a solar cell, a solar cell array, a solar cell panel or a solar
cell module.
3. The system of claim 1, wherein the switch component is
integrated within one solar cell element, wherein the integrated
switch component comprises one or more MOS-based switches
integrated within a corresponding solar cell element.
4. The system of claim 1, wherein the switch component is discrete
from the solar cell element, wherein the discrete switch component
comprises, a MOS (metal oxide semiconductor) transistor comprising
PMOS, NMOS, LDMOS, and VDMOS; a bipolar transistor comprising NPN,
PNP or IGBJT (insulated gate bipolar transistor); a FET (field
effect transistor) comprising PFET or NFET; or a mechanically
operated switch from a configuration comprising SPST (single pole
single throw), SPDT (single pole double throw), SOMT (single pole
multiple throw), DPST (double pole single throw), DPDT (double pole
double throw), and DPMT (double pole multiple throw).
5. The system of claim 1, wherein each solar cell element comprises
one or two external contacts.
6. The system of claim 1, wherein each switch component connects
all adjacent solar cell elements through the at least one switch to
form the super connection.
7. The system of claim 1, further comprising a panel having 6
super-connected solar cell elements.
8. The panel of claim 7, wherein each switch component of the panel
comprises two switches.
9. The panel of claim 7, further comprising: a first connection
arrangement of 1.times.6 having 1 loop of 6 solar cell elements
connected in series providing two connection contacts for the
panel; a second connection arrangement of 2.times.3 having 2 loops
with each loop comprising 3 solar cell elements connected in series
providing four connection contacts for the panel; a third
connection arrangement of 3.times.2 having 3 loops with each loop
comprising 2 solar cell elements connected in series providing six
connection contacts for the panel; or a forth connection
arrangement of 6.times.1 having 6 loop with each loop comprising 1
solar cell element providing eight connection contacts or more for
the panel.
10. The system of claim 1, further comprising a panel comprising 12
super-connected solar cell elements.
11. The panel of claim 10, wherein each switch component of the
panel comprises two or three switches.
12. The panel of claim 10, further comprising: a first connection
arrangement of 1.times.12 having 1 loop of 12 solar cell elements
connected in series providing two connection contacts for the
panel; a second connection arrangement of 2.times.6 having 2 loops
with each loop comprising 6 solar cell elements connected in series
providing four connection contacts for the panel; a third
connection arrangement of 3.times.4 having 3 loops with each loop
comprising 4 solar cell elements connected in series providing four
connection contacts for the panel; a forth connection arrangement
of 4.times.3 having 4 loops with each loop comprising 3 solar cell
elements connected in series providing eight connection contacts
for the panel; a fifth connection arrangement of 6.times.2 having 6
loops with each loop comprising 2 solar cell elements connected in
series providing ten connection contacts for the panel; or a sixth
connection arrangement of 12.times.1 having 12 loop with each loop
comprising 1 solar cell element providing ten connection contacts
or more for the panel.
13. The system of claim 1, wherein each solar cell element further
comprises a battery or a capacitor.
14. A by-passing connection system according to claim 1 comprising:
one or more underperforming solar cell elements disconnected from
the super connection of the plurality of solar cell elements by a
setting of one or more corresponding switches; and a second super
connection of remaining solar cell elements of the plurality of
solar cell elements.
15. The system of claim 14, wherein the second super connection
comprises one or more loops of solar cell series according to a
power output
16. A method for connecting a solar cell element comprising:
providing a plurality of switch components, wherein each switch
component comprises at least one switch; connecting one or more
switches of the plurality of switch components with each solar cell
element of a plurality of solar cell elements such that each solar
cell element is super connected with one or more adjacent solar
cell elements; and setting each switch of the connected switch
components according to a desired connection arrangement of the
plurality of solar cell elements.
17. The method of claim 16, further comprising simplifying the
super connection of the plurality of solar cell elements by
effectively removing a switch component or a crossing wire.
18. The method of claim 17, further comprising re-setting each
switch of the plurality of switch components to provide a second
connection arrangement for a second power output.
19. A method for bypassing an underperforming solar cell according
to the method of claim 16 comprising: disconnecting one or more
underperforming solar cells by turning off one or more associated
switches; and super-connecting remaining solar cell elements of the
plurality of solar cell elements.
20. The method of claim 19, wherein the super-connected remaining
solar cell elements comprise one or more loops of solar cell series
according to a power output.
Description
RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Patent Application Ser. No. 61/147,888, filed Jan. 28, 2009, which
is hereby incorporated by reference in its entirety
DESCRIPTION OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to solar cells and, more
particularly, to devices and connection systems of solar cells, and
methods for forming and arranging solar cells.
[0004] 2. Background of the Invention
[0005] Solar energy is a potentially large alternative energy
source. The most common form of solar cells is based on the
photovoltaic (PV) effect in which light falling on a two-layer
semiconductor device produces a photovoltage or potential
difference between the layers. Typically, such cells are connected
together in series in order to provide large working voltages. For
example, an average panel usually includes 10 to 36 full-sized
solar cells connected in series, producing 6-20V and 10-100
watts.
[0006] There are certain shortcomings, however, produced by the
series configured solar cell panel. For example, the solar panel is
very sensitive to the output of individual cells. Particularly, in
the case of a failure of any single solar cell in the series, the
entire row of solar cells is lost due to this undesirable
single-point failure. In addition, whenever sunlight is not cast
evenly upon the solar cell panel, such as when part of the solar
cell panel is in the shade or a shadow, the solar cells receiving
more light will produce a greater current than the solar cells
receiving less light. In that case, the current output by each row
of the cells will be limited to the lowest current produced by any
one solar cell in the row. This, in turn, causes a drop in output
power for the solar cell panel. Further, such issues may become
more important, as solar technology moves from commercial settings
into residential settings. This is because residential settings for
solar cells will have limited sighting (or location) options and
will potentially suffer from poorer maintenance than in a
commercial setting.
[0007] Conventional methods to solve these failures include use of
by-pass diodes. In this case, failed cells may be bypassed as the
voltage drop across the cells increases, but this is not a good
solution when there is more than one solar cell having lower output
in the series of solar cells.
[0008] Thus, there is a need to overcome these and other problems
of the prior art and to provide devices, and connection systems of
solar cells and methods for forming and arranging solar cells.
SUMMARY OF THE INVENTION
[0009] According to various embodiments, the present teachings
include a solar cell connection system. The connection system can
include a plurality of solar cell elements and a plurality of
switch components that each switch component can have at least one
switch. At least one solar cell element of the plurality of solar
cell elements can be associated with one or more adjacent switches
of the plurality of switch components to form a super connection
with one or more adjacent solar cell elements. Each associated
switch can be set to support a connection arrangement of the
plurality of solar cell elements for a controlled power output.
[0010] According to various embodiments, the present teachings also
include a by-passing connection system. In this system, one or more
underperforming solar cell elements can be disconnected from the
super connection of the plurality of solar cell elements by a
setting of one or more corresponding switches. The remaining solar
cell elements of the plurality of solar cell elements can then be
super-connected to have a second super connection and provide a
desired power output.
[0011] According to various embodiments, the present teachings
further include a method for connecting a solar cell element. In
this method, a plurality of switch components with each switch
component having at least one switch can be provided. One or more
switches of the plurality of switch components can be connected
with each solar cell element of a plurality of solar cell elements
such that each solar cell element can be super connected with one
or more adjacent solar cell elements. Each switch of the connected
switches can then be set according to a desired connection
arrangement of the plurality of solar cell elements.
[0012] According to various embodiments, the present teachings
further include a method for bypassing an underperforming solar
cell. In this method, one or more underperforming solar cells can
be disconnected or by-passed by turning off associated switches.
The remaining solar cell elements of the plurality of solar cell
elements can then be super-connected to provide a desired
connection arrangement and power output.
[0013] Additional objects and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
of the invention. The objects and advantages of the invention will
be realized and attained by means of the elements and combinations
particularly pointed out in the appended claims.
[0014] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention and together with the description,
serve to explain the principles of the invention.
[0016] FIG. 1A depicts an exemplary integrated solar cell device in
accordance with the present teachings.
[0017] FIG. 1B depicts a second exemplary integrated solar cell
device in accordance with the present teachings.
[0018] FIG. 1C depicts a cross section of the exemplary solar cell
devices of FIGS. 1A-1B in accordance with the present
teachings.
[0019] FIG. 2 depicts an additional exemplary solar cell device in
accordance with the present teachings.
[0020] FIG. 3 depicts an exemplary solar sensor in accordance with
the present teachings.
[0021] FIG. 4 depicts a cross-section of an exemplary solar sensor
portion in the direction A-A' of the device shown in FIG. 3 using
the exemplary integrations of FIGS. 1A-1C in accordance with the
present teachings.
[0022] FIG. 5 represents an exemplary solar cell device in
accordance with the present teachings.
[0023] FIGS. 6A-6B depict exemplary super connection systems for
solar cell elements in accordance with the present teachings.
[0024] FIGS. 7A-7C depict various connection systems for an
exemplary solar cell panel in accordance with the present
teachings.
[0025] FIGS. 8A-8C depict various connection systems for by-passing
underperforming solar cells in accordance with the present
teachings
[0026] It should be noted that some details of the FIGS. have been
simplified and are drawn to facilitate understanding of the
inventive embodiments rather than to maintain strict structural
accuracy, detail, and scale.
DESCRIPTION OF THE EMBODIMENTS
[0027] Reference will now be made in detail to the exemplary
embodiments of the invention, examples of which are illustrated in
the accompanying drawings Wherever possible, the same reference
numbers will be used throughout the drawings to refer to the same
or like parts. In the following description, reference is made to
the accompanying drawings that form a part thereof, and in which is
shown by way of illustration specific exemplary embodiments in
which the invention may be practiced. These embodiments are
described in sufficient detail to enable those skilled in the art
to practice the invention and it is to be understood that other
embodiments may be utilized and that changes may be made without
departing from the scope of the invention. The following
description is, therefore, merely exemplary
[0028] Exemplary embodiments provide a solar cell device, and
method for forming the solar cell device by integrating a switch
component into a solar cell element. Exemplary embodiments also
provide a solar sensor and methods for forming and using the solar
sensor to detect a defected or a shaded solar cell area. Exemplary
embodiments also provide a connection system of the solar cell
elements and method for super-connecting solar cell elements so as
to provide a desired connection path or a desired power output.
Exemplary embodiments further provide a system and a method for
by-passing underperforming solar cells of a solar cell
component.
[0029] As used herein, the term "solar cell element" can include a
single solar cell, a solar cell array such as a group or a series
of solar cells, or a solar cell panel (or solar cell module) such
as a group of solar cell arrays. The solar cell element can have at
least two solar cell terminals. In various embodiments, the
disclosed "solar cell element" as well as the related devices,
systems and methods can further be extended to include, for
example, a battery or a capacitor.
[0030] The switch component can include one or more switches that
are either integrated into the solar cell terminal itself or added
separately from the solar cell as discrete elements. In various
embodiments, switches that are integrated into either or both of
the solar cell terminals can include MOS-based structures
including, but not limited to, VDMOS (vertically diffused metal
oxide semiconductor) or LDMOS (laterally diffused metal oxide
semiconductor) transistors that can utilize the corresponding solar
cell terminal as, for example, the drain of the DMOS-based
structure. Such DMOS elements can include both N-type and P-type
DMOS (NDMOS and/or PDMOS) depending on the polarity of the solar
cell terminal. In various embodiments for integrated switches, a
DMOS configuration can be preferred as it allows for a low on-state
resistance (Rdson) without reducing the output of the solar cell
element. While a bipolar transistor switch, including both vertical
and lateral PNP and NPN transistors, can also be integrated into
one or both terminals of the solar cell element, these are not
preferred for the integration due to their high voltage drop even
when operated in their saturation regions.
[0031] For embodiments that include discrete switches that are not
integrated into the solar cell terminals, there are a variety of
switches that can be used including, but not limited to, any MOS
(metal oxide semiconductor) transistor including PMOS, NMOS, LDMOS,
and VDMOS; any bipolar transistor including NPN, PNP or IGBJT
(insulated gate bipolar transistor); any FET (field effect
transistor) including PFET or NFET; or any mechanically operated
switches including configurations that use conventional
mechanically actuated or electrically actuated (such as relays)
switches in SPST (single pole single throw), SPDT (single pole
double throw), as well as SPMT (single pole multiple throw)
configurations for integrations that connect to a single or both
terminals of the solar cell element, or switches in DPST (double
pole single throw), DPDT (double pole double throw), as well as
DPMT (double pole multiple throw) configurations that connect to
both terminals of the solar cell element.
[0032] In various embodiments, the MOS-based switches can be
integrated with one or both terminals of the solar cell element.
The integrated solar cell terminal(s) can be combined with one of a
source region and a drain region of the MOS-based switch component
to have a common contact for the disclosed solar cell device. In
some embodiments, the integrated or combined solar cell terminal
can still keep its contact, which is also referred to herein as an
"external contact", in order to provide more connection
flexibilities.
[0033] As disclosed herein, the term "external contact" refers to
an electrical contact to the solar cell terminal, for example, to
bypass a switch component so as to allow a separate electrical
connection to the affected terminal of the solar cell element.
[0034] In various embodiments, when a plurality of MOS-based
switches are used for the switch component, the MOS-based switches
can be formed to have a common drain region or a common source
region according to the integration design of the solar cell
device.
[0035] FIGS. 1A-1C depict an exemplary solar cell device having a
MOS-based switch component integrated within a single solar cell in
accordance with the present teachings. Specifically, FIG. 1C
depicts schematic cross section of an exemplary solar cell device
100C according to FIGS. 1A-1B in accordance with the present
teachings.
[0036] It should be readily apparent to one of ordinary skill in
the art that the devices depicted in FIGS. 1A-1C represent
generalized schematic illustrations and that other components can
be added or existing components can be removed or modified. In
addition, although a single solar cell is depicted for the solar
cell element in FIGS. 1A-1C, one of ordinary skill in the art would
understand that other solar cell elements including, but not
limited to, a solar cell array, or a solar cell panel, can be used
for the disclosed solar cell device. Further, any solar cell
elements that are compatible with the materials and fabrication of
MOS technologies can be used for the disclosed solar cell device
110 in FIGS. 1A-1C.
[0037] It is also possible that the solar cell element 110 in FIGS.
1A-1B can represent a conventional battery or even a high value
capacitor. Such configurations can allow for cell balancing
applications in battery packs, for example, or other sources of
power that include multiple connected batteries or capacitors.
[0038] For simplicity, FIGS. 1A-1C show an exemplary integration of
one MOS-based structure 120 with an exemplary single solar cell
110. As shown, the solar cell 110 can have two terminals or two
contact diffusion regions 112 and 114. The MOS-based structure 120
can have, for example, a drain region 123, a source region 129 and
a gate 126.
[0039] The MOS-based structure 120 can be used as a switch using
the gate 126 to control, e.g., to turn on and off, the solar cell
110, so as to control power output, e.g., current and/or voltage,
of the solar cell 110. In an exemplary embodiment, the MOS-based
structure 120, such as a VDMOS, can only need a breakdown voltage
of a few volts and can be designated with a low on-state resistance
(Rdson).
[0040] In the illustrated examples, the MOS-based structure 120 can
be integrated with the exemplary terminal 114 of the solar cell
110. For example, the drain region 123 of the MOS-based structure
120 can be integrated or combined with the terminal 114 of the
solar cell 110. The integrated solar cell terminal 114 may keep its
own external contact (see 114c) as shown in FIGS. 1A and 1C, or
alternatively, the external contact 114c may be removed using the
common contact with the drain region 123 of the MOS-based structure
120, as shown in FIG. 1B.
[0041] As shown in FIG. 1C, an exemplary DMOS switch 120 can be
integrated into one of the terminals of a conventional solar cell,
i.e., the n terminal 114, in order to switch the solar cell on and
off. One example of the conventional solar cells can include
silicon-based photovoltaic cells having a solar cell array or a
solar cell panel including alternating p and n contact diffusions.
In the illustrated embodiment of FIG. 1C, the n terminal of the
solar cell can be integrated by the exemplary DMOS-based structure,
although one of ordinary skill in the art would understand that any
other MOS-based switches can be used for the disclosed solar cell
device.
[0042] The device 100C can thus include a solar cell p terminal
112, a solar cell n terminal 114, and a DMOS-based structure 120
formed in a semiconductor substrate 130.
[0043] The DMOS-based structure 120 can be, for example, a vertical
DMOS-based structure that includes source regions (n+) 127 in
p-body regions 125,122, p-body contact regions 124 (e.g., a heavily
doped region p+), a drain region 123, a gate 126, and insulative
regions 105 as known by one of ordinary skill in the art.
[0044] The integrated solar cell n terminal 114, e.g., the heavily
doped (n+) region 114, can also be used as a drain region contact
of the DMOS-based structure 120. The p-body 122 and 125 can be
formed on top of the drain region 123, which can be a deep n well
formed by implantation and/or diffusion process in a p-type layer
in a typical silicon substrate (also see 130), for example. The
source region 127 and p-body region 122 can be shorted together by
the combination of a p-body contact region 124 and the
p-body-source contact metallization 129c.
[0045] In various embodiments, the electrical contacts, such as,
for example, the solar cell p-contact 112c, the solar cell
n-contact 114c, and the contacts 129c, 114c and 126 for the source
region, the drain region and the gate, can include the use of
copper interconnect and other metals that are compatible with solar
cell and semiconductor processing. In various embodiments, the gate
material can further include, e.g., polysilicon that is ion
implanted or in-situ doped to be N+ or P+ in polarity.
[0046] In some embodiments, the solar cell n terminal contact 114c
can be used as an external contact for the solar cell device 110C
(also see FIG. 1A). In other embodiments, the cell n terminal
contact 114c can be removed (not shown) from FIG. 1C, as also
indicated in FIG. 1B.
[0047] In various embodiments, the conductivity of semiconductor
regions, i.e., the use of p and n type semiconductor regions, can
be reversed for the solar cell devices 100C along with any other
devices disclosed herein.
[0048] In various embodiments, a plurality of switches can be
included for the switch component in the disclosed solar cell
device. For example, FIG. 2 depicts another exemplary solar cell
device in accordance with the present teachings. It should be
readily apparent to one of ordinary skill in the art that the
device 200 depicted in FIG. 2 represents a generalized schematic
illustration and that other components/devices can be added or
existing components/devices can be removed or modified.
[0049] As shown in FIG. 2, the exemplary solar cell device 200 can
include a solar cell 110 having two terminals (or contact
diffusions) 112 and 114. The device 200 can also include a number
of MOS-based switches 120a-c integrated with one of the solar cell
terminals, e.g., the terminal 114. In various embodiments, as
similarly described in FIGS. 1A-1C, the terminal 114 may or may not
exist but sharing a common contact with the drain region 123 of the
MOS-based switch component 120.
[0050] In the specific embodiment of FIG. 2, while three MOS-based
structures 120 are integrated with the solar cell 110 sharing a
common drain region 123 for the solar cell device 200, one of
ordinary skill in the art will understand that any number of switch
structures can be integrated within the solar cell. In addition,
the formation structure of the device 200 can be similar to that
shown in FIG. 1C, except that more switches (e.g., two more as for
the device 200) can be formed in series within the solar cell
device sharing a common drain region. In various embodiments, the
multiplicity of switches for the disclosed solar cell device can
provide a variety of connection flexibilities with any other
components that are related to the solar cell.
[0051] Various embodiments can thus include a method for forming a
solar cell device. For example, a semiconductor solar cell element
that includes a p contact diffusion region and an n contact
diffusion region can first be provided or formed in a semiconductor
substrate. A MOS-based structure can then be integrated with at
least one of the n contact diffusion region and the p contact
diffusion region in the semiconductor substrate so as to control
the semiconductor solar cell element as a switch. In various
embodiments, a plurality of MOS-based structures can be formed in
the semiconductor substrate having a common drain region or a
common source region.
[0052] In various embodiments, the integrated plurality of
MOS-based structures can have a breakdown voltage consistent with
the number of solar cells in the stack. For example, a single solar
cell switch can operate with a breakdown voltage of about 1 or 2
volts, while solar cell stacks can require a breakdown voltage of
about 10 volts.
[0053] Various embodiments can also include a solar sensor and its
formation in accordance with the present teachings. For example,
FIG. 3 depicts a portion of an exemplary solar sensor component 300
in accordance with various embodiments of the present teachings. It
should be readily apparent to one of ordinary skill in the art that
the sensor 300 depicted in FIG. 3 represents a generalized
schematic illustration and that other components/devices can be
added or existing components/devices can be removed or
modified.
[0054] As shown, the solar sensor component 300 can include a
plurality of solar cell areas 310, and a plurality of switch
components 320. The solar sensor component 300 can include various
sensor elements with each sensor elements (e.g., 300a or 300b)
including one solar cell area (e.g., 310a or 310b) and one switch
component (e.g., 320a or 320b) associated therewith.
[0055] Each solar cell area 310 can be defined by, e.g., a single
pixel in the array having a pixel size P and divided from the solar
sensor component 300. The pixel size P can depend on a diffusion
length of holes and/or electrons drifting in the semiconductor. For
example, in silicon photovoltaic cells, when solar radiation falls
on a silicon n-p junction, photons with wavelength less than 1.13
.mu.m can generate electron-hole pairs. The electric field in the
depletion layer can drive the electrons to the n-type side and the
holes to the p-type side. This can separate most of the electrons
and holes before they can recombine. The "diffusion length" can be
determined by how far the minority current carriers, electrons or
holes, can drift or diffuse in the area before their recombination
or before reaching the junction. Each solar cell area 310 can
therefore include at least one single solar pixel.
[0056] Each switch component 320 can independently address the
associated solar cell area 310. In various embodiments, each switch
component 320 can be integrated within one of the solar cell areas
310 or can be discrete from the corresponding solar cell area
310.
[0057] Note that, although the solar sensor component shown in FIG.
3 includes 36 solar sensor elements or solar sensor areas in a
6.times.6 array, one of ordinary skill in the art would understand
that any other numbers of solar sensor elements or any other
suitable arrangements/arrays of the solar sensor elements/areas can
be used for the disclosed solar sensor component 300.
[0058] FIG. 4 depicts a cross-section portion of an exemplary solar
sensor 400 using the integration shown in FIG. 1C in accordance
with the present teachings. The cross-section of FIG. 4 shows a
solar sensor portion in the direction of A-A' of FIG. 3, wherein
the portion can include sensor elements 300a-b.
[0059] In various embodiments, the integration of FIG. 1 can be
used as an example for each sensor element. As shown, the device
100C shown in FIG. 1C can be used as an element 300a or 300b for
the solar sensor 400, wherein each switch component independently
control the associated or corresponding solar cell.
[0060] In various embodiments, the solar sensor 300 and/or 400 can
further include a readout component used to display an electric
output from each individual solar cell area controlled by the
corresponding independent switch component. Typically, for a solar
cell, an electrical load resistance R can be connected across the
semiconductor junction. The electrons and holes can produce a
current, and the energy in the solar radiation can then be
converted into electrical energy in the circuit.
[0061] When one solar cell area of the solar cell sensor has
defects, impurities or is shaded, the diffusion length and the life
time of the current carriers, i.e., the holes or the electrons, can
be reduced. Electronic power output may not be measured for this
individual solar cell area. Defects or shade can then be detected.
In one embodiment, the solar sensor 300 or 400 can be used for
sensing light dark areas. For example, shade or photon irradiation
detection can be performed by locally collecting the electric
outputs.
[0062] Various embodiments can further include a method for forming
solar sensors, for example, using the method described in FIGS.
1A-1C and 2. In another example, the method can include first
forming or providing a solar cell component having a plurality of
solar cell areas. Each solar cell area can be defined by a pixel of
a diffusion length of the electrons or holes. A plurality of
switches can then be formed or provided with each switch
independently controlling one solar cell area In order to determine
a defected solar cell area or a shaded area, the electric output of
each solar cell area can be monitored.
[0063] In various embodiments, super connection schemes, systems
and methods can be provided for solar cell based applications. The
super connection can provide a variety of arrangements and
connection paths for solar cell elements with a desired electric
output.
[0064] For simplicity of illustration, FIG. 5 represents an
exemplary symbol for the solar cell devices in accordance with the
present teachings. As shown, the solar cell device 500 can include
a solar cell element 510 having two terminals 512 and 514. The
solar cell element 510 can be, e.g., a single solar cell as shown
in FIGS. 1A-1C and FIG. 2; a group of solar cells, such as a solar
cell array; and/or a solar cell panel, such as a group of solar
cell arrays.
[0065] The solar cell device 500 can also include a switch
component 520 having one or more switches 520a-c associated with
one of the solar cell terminals, e.g., 514. In various embodiments,
the switch component 520 can be an integrated switch component,
e.g., formed within a solar cell element as shown in FIGS. 1C and
FIG. 4; or a discrete switch component from the solar cell element
510. Any suitable switch as disclosed herein or as known to one of
ordinary skill in the art can be used for the discrete switch
component.
[0066] Although three switches are depicted in FIG. 5 for the
switch component 520, various embodiments can include a number of
switches that is more than or less than three for the switch
component 520.
[0067] FIGS. 6-8 provide various embodiments of connection systems
and connection methods of solar cell elements. In various
embodiments, the term "super connection" refers to a connection
scheme that provides all possible cross connections between any
adjacent solar cell elements. The super connection can be fulfilled
by associating switch components with each solar cell element,
wherein each switch component can further include various numbers
of switches. Such super connection can provide flexibility to wire,
e.g., an array or a panel of the solar cell elements, and therefore
provide flexibility on power outputs. In an exemplary embodiment, a
number of solar cell elements can be super connected in a manner of
series-parallel management. That is, one or more series of solar
cell elements can be super connected in parallel.
[0068] FIGS. 6A-6B depict exemplary super connection systems in
accordance with the present teachings. It should be readily
apparent to one of ordinary skill in the art that the systems
depicted in FIGS. 6A-6B represent generalized schematic
illustrations and that other components/devices can be added or
existing components/devices can be removed or modified.
[0069] In various embodiments, elements, components and devices
related to the solar cell device 500 shown in FIG. 5 can be used as
examples for the super connections of solar cell elements.
[0070] In FIG. 6A, the connection system 600A can include a
plurality of solar cell elements 610a-f with each solar cell
element associated with one or more adjacent switches 620a-f from a
plurality of switch components to form the super connection. In
various embodiments, switches connected to a specific solar cell
element can be from different switch components and each switch
component can include at least one switch. Solar cell elements can
therefore be super interconnected through a variety of connections
using, e.g., the associated switches 620, and/or external contacts
612a-f or 614a-f. Having the super connected system, each of the
associated switches can be set to support a desired connection
arrangement of the plurality of solar cell elements for a
controlled power output.
[0071] In FIG. 6A, for example, the solar cell element 610b can be
super connected using an exemplary series-parallel connection
scheme. As shown, the solar cell element 610b can be connected to a
first adjacent solar cell element 610a through the external contact
612b and the switch 620a1; the solar cell element 610b can also be
connected to a second adjacent solar cell element 610c through the
switch 620b1 and an external contact 612c; the solar cell element
610b can further be connected to a third adjacent solar cell
element 610e through the external contact 612b and the switch
620e2, and/or through the switch 620b2 and the external contact
612e; and, the solar cell element 610b can even further be
connected to a forth or fifth adjacent solar cell element 610d or
610f through, for example, the crossing wire 634/635 or the cross
wire 632/633 along with related switches.
[0072] In various embodiments, when more solar cell elements are
needed to be connected with the exemplary solar cell element 610b,
more switches 620b, more external contacts such as 614b and/or more
crossing wires can be available as desired. Likewise, other solar
cell elements, e.g., 610a, and 610c-f, in FIG. 6A can go through
such super connection process.
[0073] In various embodiments, the super connection of FIG. 6A can
be simplified or cleaned by removing one or more redundant switch
component(s) or crossing wire(s) using some common nodes instead.
For example, the switch components 620c, 620e and 620f as well as
the crossing wires 631 and 633 can be "effectively removed" from
the connection system 600A leaving a "simplified" super connection
system 600B shown in FIG. 6B.
[0074] As used herein, the "effectively removed" switches and
crossing wires may physically exist, i.e., not necessarily to be
physically removed, but may be electrically switched off with no
current flowing there-through. For example, switches can be
"effectively removed" by an electrical by-passing, e.g., using
external contacts; and crossing wires can be "effectively removed"
by suitable switch settings with no current allowed to flow
through.
[0075] As shown in FIG. 6B, the connection system 600B can include
a plurality of solar cell elements 610a-f with at least one solar
cell element associated with one or more adjacent switches 620a-f
from a plurality of switch components to form the super
connection.
[0076] In various embodiments, each switch that is associated with
the solar cell elements can be set to support a desired connection
arrangement of the plurality of solar cell elements for a
controlled power output That is, by controlling the switches, any
desired configurations and outputs can be obtained.
[0077] FIGS. 7A-7C depict various connection systems for an
exemplary panel having 6 solar cell elements in accordance with the
present teachings. As shown, the connection systems use a box 705
to show one solar cell device (e.g., the device 500 shown in FIG.
5) including a solar cell element and the associated switches. It
should be readily apparent to one of ordinary skill in the art that
the systems depicted in FIGS. 7A-7C represent generalized schematic
illustrations and that other components/devices/boxes can be added
or existing components/devices/boxes can be removed or
modified.
[0078] In various embodiments, the connection systems shown in
FIGS. 7A-7C can be obtained by first super connecting the exemplary
6 solar cell elements, for example, as shown in FIG. 6A or 6B, and
then setting each switch associated with the solar cell elements to
form various connection arrangements as needed.
[0079] In one embodiment when series-parallel management is used
for the exemplary 6 solar cell panel, possible connection
arrangements can include, for example, a 1.times.6 arrangement (see
FIG. 7A), a 2.times.3 arrangement (see FIG. 7B), a 3.times.2
arrangement (see FIG. 7C), and/or a 6.times.1 arrangement (not
shown). In this case, each switch component can have two switches
for the solar cell panel that has 6 solar cell elements.
[0080] In FIG. 7A, the 1.times.6 connection arrangement can have 1
loop (see 700a) of 6 solar cell elements (see boxes 705) connected
in series providing two connection contacts 700a1 and 700a2 for the
panel.
[0081] In FIG. 7B, the 2.times.3 connection arrangement can have 2
parallel loops (see 700b) of 3 solar cell elements (see boxes 705)
connected in series providing four connection contacts 700b1-700b4
for the panel.
[0082] In FIG. 7C, the 3.times.2 connection arrangement can have 3
parallel loops (see 700c) of 2 solar cell elements (see boxes 705)
connected in series providing six connection contacts 700c1-700c6
for the panel.
[0083] Such connection arrangements 700a-c can be obtained from
switching the super connected solar cell system as shown in FIG. 6A
or 6B. For example, in order to have a connection arrangement of
1.times.6 of FIG. 7A, switches of the super connected system 600A
(see FIG. 6A) including, for example, 620a1, 620b1, 620c1, 620d1,
620e1 can be turned on, while switches of 620a2, 620b2, 620c2,
620d2, 620e2, 620f1 and 620f2 can be turned off. In addition,
crossing wires 631, 632, 633, 634 and 635 (see FIG. 6A) can be
effectively removed because there is no current path due to the
switch settings, while crossing wire 636 stay connected because
corresponding switch settings allow current flow. Although the
crossing wires 631, 632, 633, 634 and 635 are not illustrated in
FIG. 7A, these "effectively removed" crossing wires may physically
exist but be electrically switched off. Further, in various
embodiments, some of the switches (e.g., switches 620c1 as well as
the switch 620c2) can be bypassed by using external contacts (e.g.,
contact 614c) for this illustrated connection arrangement.
[0084] In various embodiments, the connection arrangement of FIG.
7A can be obtained by setting switches from the simplified super
connection system of FIG. 6B.
[0085] Likewise, the connection systems shown in FIG. 7B and FIG.
7C can also be obtained by setting related switches from the super
connection system of FIGS. 6A-6B, as similarly described for the
arrangement process of FIG. 7A. In addition, some of the crossing
wires may be "effectively removed" from the super connection system
shown in FIGS. 6A-6B using switch settings, which are not
necessarily physically removed. For example, for the connection
system 700b, all the crossing wires 631-636 can be "effectively
removed", while for the connection system 700c, crossing wires 631,
633, and 635 can be "effectively removed".
[0086] In this manner, by choosing suitable switches or by
re-switching suitable switches of the disclosed super connection
system, the connections of the solar cell elements can be
rearranged. In various embodiments, the solar cell panel can have
various number of solar cell elements connected as desired from a
related super connection system using the exemplary systems and
methods shown in FIGS. 6-7.
[0087] For example, the solar cell panel can also have 12 solar
cell elements that need to be connected. For a desired electric
output and thus a desired solar cell connection, the 12 solar cell
elements can be super connected with each solar cell element
interconnected with all adjacent solar cell elements by switches,
external contacts and/or crossing wires using similar methods
described in FIGS. 6-7.
[0088] As a result, various configurations can be obtained for the
12 solar cell elements including: (1) a 1.times.12 connection
arrangement having 1 loop of 12 solar cell elements connected in
series providing two connection contacts for the panel; (2) a
2.times.6 connection arrangement having 2 parallel loops of 6 solar
cell elements connected in series providing four connection
contacts for the panel; (3) a 3.times.4 connection arrangement
having 3 parallel loops of 4 solar cell elements connected in
series providing four connection contacts for the panel; (4) a
4.times.3 connection arrangement having 4 parallel loops of 3 solar
cell elements connected in series providing eight connection
contacts for the panel; (5) a 6.times.2 connection arrangement
having 6 parallel loops of 2 solar cell elements connected in
series providing ten connection contacts or more for the panel;
and/or (6) a 12.times.1 connection arrangement having 12 individual
solar cell elements for the panel.
[0089] In various embodiments, the super connection system
disclosed herein can be used to bypass one or more underperforming
solar cell elements (e.g., that are at least partially shaded, or
defective) from groups of solar cell elements. Thus, if a single
solar cell element fails, there can be alternate paths by which the
output power of all other solar cell elements/devices can
contribute to the total output power of the solar cell array or
panel. In various embodiments, after by-passing the underperforming
solar cell elements, e.g., using switches, all of the other
remaining solar cell elements can be arranged or re-arranged
according to the disclosed super connection process.
[0090] Still using the super connection system 600A as an example,
FIGS. 8A-8C show various by-passing connection systems in
accordance with the present teachings. It should be readily
apparent to one of ordinary skill in the art that the systems
depicted in FIGS. 8A-8C represent generalized schematic
illustrations and that other components/devices can be added or
existing components/devices can be removed or modified.
[0091] In various embodiments, underperforming solar cell(s) of a
plurality of solar cell elements can first be disconnected, e.g.,
by turning off associated switches, while other solar cell elements
of the plurality of solar cell elements can remain connected or can
be reconnected or rearranged to provide a second suitable super
connection. In various embodiments, the rearranged other solar cell
elements can include one or more loops of solar cell series
according to a power output.
[0092] In one exemplary embodiment shown in FIG. 8A, when one solar
cell device 805e underperforms, the solar cell device 805e,
including the related solar cell element (also see the solar cell
element 610e of FIG. 6A) and/or its related switches, can be
disconnected, e.g., by turning off all associated switches, from
the plurality of solar cell devices. Remaining solar cell devices
(see 610a-d and 610f) can then be re-arranged or re-super
connected, e.g., connected in series (see 800a), whereby providing
connection contacts of 800a1 and 800a2.
[0093] Likewise, in another exemplary embodiment shown in FIG. 8B,
when another solar cell device 805f (also see the solar cell
element 610f of FIG. 6A) underperforms and is disconnected from the
plurality of solar cell devices, the other remaining solar cell
devices (see 610a-e) can be re-arranged or re-super connected in
one series (see 800b), whereby providing connection contacts of
800b1 and 800b2.
[0094] In an additional exemplary embodiment shown in FIG. 8C, when
the solar cell device 805f underperforms and is disconnected, the
other remaining solar cell devices (see 610a-e) can be re-arranged
or re-super connected to have two loops 800c of connected solar
cell series (see 600a-c and 600d-e) providing connection contacts
of 800c1, 800c2, 800c3 and 800c4.
[0095] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values set forth in the specific examples are
reported as precisely as possible. Any numerical value, however,
inherently contains certain errors necessarily resulting from the
standard deviation found in their respective testing measurements.
Moreover, all ranges disclosed herein are to be understood to
encompass any and all sub-ranges subsumed therein. For example, a
range of "less than 10" can include any and all sub-ranges between
(and including) the minimum value of zero and the maximum value of
10, that is, any and all sub-ranges having a minimum value of equal
to or greater than zero and a maximum value of equal to or less
than 10, e.g., 1 to 5. In certain cases, the numerical values as
stated for the parameter can take on negative values. In this case,
the example value of range stated as "less than 10" can assume
values as defined earlier plus negative values, e.g. -1, -1.2,
-1.89, -2, -2.5, -3, -10, -20, -30, etc.
[0096] While the invention has been illustrated with respect to one
or more implementations, alterations and/or modifications can be
made to the illustrated examples without departing from the spirit
and scope of the appended claims. In addition, while a particular
feature of the invention may have been disclosed with respect to
only one of several implementations, such feature may be combined
with one or more other features of the other implementations as may
be desired and advantageous for any given or particular function.
Furthermore, to the extent that the terms "including", "includes",
"having", "has", "with", or variants thereof are used in either the
detailed description and the claims, such terms are intended to be
inclusive in a manner similar to the term "comprising." As used
herein, the term "one or more of" with respect to a listing of
items such as, for example, A and B, means A alone, B alone, or A
and B. The term "at least one of" is used to mean one or more of
the listed items can be selected.
[0097] Other embodiments of the invention will be apparent to those
skilled in the art from consideration of the specification and
practice of the invention disclosed herein. It is intended that the
specification and examples be considered as exemplary only, with a
true scope and spirit of the invention being indicated by the
following claims.
* * * * *