Solar Modules Having Solar Sub Cells With Matrix Connections Between The Solar Sub Cells
Abstract:
A solar power generation system for providing a predetermined operating power level and predetermined operating voltage level requirement, the system including at least one solar-array panel, wherein each of the at least one solar-array panels includes a multiplicity of PV solar sub cells, wherein a preconfigured number of the PV solar sub cells are electrically connected in series to form a serial-unit or each individual serial unit having just one PV solar sub cell, and wherein a preconfigured number of the serial units are electrically connected in series to form a string of serial-units. The PV solar sub cells are also connected in parallel to neighboring sub cells to form a crisscross matrix array that facilitates bypassing malfunctioning serial units, thereby improving the performance of the system. A PV solar sub cell is at least 50% smaller in area than a regular PV solar cell.
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Notices, Deadlines & Correspondence
FIELD OF THE INVENTION
The present invention relates to a solar array module system for generating electric-power and more particularly, to a non-monolithic solar array module system having PV solar sub cells interconnected in a crisscross configuration.
BACKGROUND OF THE INVENTION
Non-monolithic photovoltaic (PV) cells that are subdivided into smaller sub cells that are interconnected in series, are known in the art.
Solar array modules, having solar cells that are interconnected in a crisscross electrical matrix are also known in the art. See, for example, PCT Published Application
No. WO/2011/089607 ('607) filed on January 23rd, 2011, and PCT Published Application No. WO/2013/144963 ('963) filed on March 30th, 2013, by the same inventor as the instant application and which is owned in common, which are hereby incorporated by reference in their entirety.
The electrical current generated in a PV cell brings about losses of power caused by:
1. The busbar of each solar cell.
2. The solder points between PV cells and external conductors and other soldered points.
3. Conductors interconnecting PV cells into string of cells.
4. Conductors connecting string of PV cells to respective junction boxes.
These overall power losses decrease the output power of a PV panel.
A typical non-monolithic PV panel consists of dozens of quadratic PV cells. A typical quadratic cell size is approximately 15cm X 15cm and provides electrical power of around (all numbers are given by way of example only, with no limitations):
0.5V *8A = 4W
With reference to the drawings. Fig. 1., showing the equivalent circuit 20 of a PV cell, it is evident that the current 1(80) produced by the solar cell is equal to that produced by the current source 70, minus that which flows through the diode 30, minus that which flows through the shunt resistor 40:
where
* I (80) = output current (ampere)
* II (82) = photo-generated current (ampere)
* //) (84) :::: diode current (ampere)
* Isn (86) ::: shunt current (ampere),
The values of h, ID, RS and RSH are dependent upon the physical size of the solar cell. When comparing otherwise identical technology solar cells, a first cell with twice the junction (light sensitive) area of a second cell generates double the h and 780 is also approximately twice higher.
Regardless of the PV cell size, the cell output voltage 60 remains almost unchanged.
For example, if instead of a regular 15cm X 15cm (proximal dimensions) quadratic cell, herein after also referred to as "regular size solar cell", "regular PV solar cell", "regular solar cell", or "regular cell", two cells of size 15cm X 7.5cm, or three cells of size 15cm X 5cm each are used (or other smaller (sub) sizes of cells that combine into a total of 15cm X 15cm area, thereby the power of the regular 15cm X 15cm quadratic cell and the sum of the combined sub cells' power are equivalent (not considering smaller power losses and improved fill-factor of sub-cells, because actually, they provides higher power yield), then: the smaller size cell of 15cm X 7.5cm produces a voltage of around 0.5 V, but provides half the magnitude of current of the big cell (15cm * 15cm), i.e., I = 8 A / 2 = 4A.
Similarly, a sub cell of 15cm X 5cm provides a current I = 8A 1 3 = 2.66A. Therefore, the power losses caused by the three times smaller size solar cell output current on the same soldering points of cells, same busbars on solar cells, same conductors interconnecting PV cells to strings of cells, same conductors connecting strings of PV cells to designated junction boxes, according to the following expression, will be significantly less than the power losses brought about by larger output current of the bigger size cell:
Plusses ~~ I R,
where R is total resistance of all of the above conductors and soldered points. The table below compares, by way of example, the power losses in 250W panel with big and small PV cells sizes:
Incorporating smaller size cells with cells matrix connection maintains all advantages of this type of cells connection and provide higher power yield from each cell and from the entire panel.
There is therefore a need and it would be advantageous to have solar array modules for producing electric-power, having solar cells that are interconnected in a crisscross electrical matrix, wherein at least some of the regular size solar cells are "replaced" by a number of equivalent sub cells, and it would be further advantageous to have at least some of the sub cells interconnected in matrix, crisscross configuration. Typically, with no limitation, a regular size solar cell is cut into the number of equivalent sub cells.
SUMMARY OF THE INVENTION
A principal intention of the present invention is to provide a non-monolithic array of solar cells that are interconnected in a crisscross electrical matrix, wherein at least some of the regular size solar cells are replaced by a number of sub cells that provide the same voltage, and wherein the smaller the solar cells are the less power losses are inflicted. The crisscross electrical matrix provides a passive rerouting of electric current when an individual solar-cell malfunctions. The solar module includes solar cells that are interconnected in a crisscross electrical matrix, wherein at least some of the "regular" size solar cells (15cmX15cm) are, for example, replaced by cutting such a regular size solar cell into a number of equivalent sub cells, and wherein the sub cells are interconnected in matrix, crisscross configuration.
Let us presume, for example, with no limitations, a common panel having 60 regular (15cmX15cm) PV solar cells 210, that is arranged in a crisscross matrix configuration of 10 columns with serial strings each consisting of 6 regular PV solar cells. Each serial string of cells 210 provides power of: 8A * (0.5V*6) = 24W. Hence, the voltage of a serial string of regular cells 210 is: 0.5V*6 = 3V, and the panel provides a total of 240W. It should be noted that a 3V panel voltage is not suitable to obtain the voltage of commonly used regular panels, and requires an additional voltage DC/DC converter 250 (see Fig. 3) to boost the panel output voltage. If each regular PV solar cells 210 is replaced by a string of 9 sub cells, connected in serial, each typically of size 15cmX1.67cm, then the current / drops to 8/9 = 0.8889A, but the voltage of serial string of sub cells is now: 0.5V*6*9 = 27V. Therefore, the total output power remains 240W. In such a case, no DC/DC converter 250 is needed and it is possible to connect all panels with crisscross matrix cells connections, with or without a Maximum Power Point Tracker (being a power optimizer), directly in series to create strings of panels, to connect strings in parallel and to connect directly to an inverter or create parallel connections of a lot of the above panels with suitable panels output voltage and connect this array to battery charger with or without a MPPT.
The advantages of multiple sub cells arranged in a crisscross matrix include: a. No DC/DC converter 250 is needed, thereby reducing the panel cost. b. Lack of need to use voltage converter enables to increase the panel energy by about 3% (in case of a 97% efficiency of converter),
c. The smaller current of the PV cells further reduces power losses.
It should be noted that orientation related descriptions such as "top", "bottom", "horizontal", "vertical" "up", "upper", "down", "low", "lower" and the like, assumes that the solar cell module is situated, with no limitations, such that the positive ("+") side of the array is considered, artificially, with no limitations, as the top side of the array, and the negative ("-") side of the array is considered, artificially, with no limitations, as the bottom side of the array. Alternatively, with no limitations, the negative ("-") side of the array is considered, artificially, with no limitations, as the top side of the array, and the positive ("+") side of the array is considered, artificially, with no limitations, as the bottom side of the array.
It should be further noted that the terms "electrical" or "electrically wired", as used herein refer to the electrical configuration of the matrix, regardless of the physical configuration of the solar cells in the solar panel. Similarly, it should be further noted that the term "physical" as used herein refers to the physical placement of solar cells in the module/panel, regardless of the electrical inter-wiring of the solar cells.
According to the teachings of the present invention there is provided a solar power generation system for providing a predetermined operating power level and predetermined operating voltage level requirement, the system including at least one solar-array panel, wherein each of the at least one solar-array panels includes a multiplicity of PV solar sub cells, wherein a preconfigured number of the PV solar sub cells are electrically connected in series to form a serial-unit or each individual serial unit having just one PV solar sub cell, and wherein a preconfigured number of the serial units are electrically connected in series to form a string of serial-units, the string of serial-units is facilitated to produce a first output voltage level.
A preconfigured number of the strings of serial-units, are electrically connected in parallel to form an array of the PV solar sub cells. In each of the strings of serial-units, each of the serial-units is also connected in parallel to the neighboring serial-units of all other strings of serial-units, to form a crisscross matrix array of the serial units, the crisscross matrix array of the PV solar sub cells is facilitated to produce a first output power level, wherein the crisscross matrix array of the serial units allows currents to bypass malfunctioning serial units, thereby improving the performance of the system; and Each of the PV solar sub cell is physically smaller than a regular PV solar cell, wherein a regular PV solar cell is a quadrangular of about 15cmX15cm and produces a voltage of about 0.5V and current of about 8 A, and wherein the PV solar sub cell is a quadrangular PV solar cell that is at least 50% smaller in area than a regular PV solar cell.
It should be noted that the voltage produced by a regular PV solar cell and by a combination of the PV solar sub cell, covering an equivalent PV area, is the same, but the current generated by the combination of the PV solar sub cell is directly proportionately smaller than the current generated by a regular PV solar cell, thereby minimizing power loses and eliminating the need for a DC/DC converter.
Optionally, each of the strings of serial-units consists of the same number of the solar cells electrically connected in series.
Optionally, the solar power generation system further including a quantity of / bypass diodes that are connected in parallel to a preconfigured number of rows of the sub cells of the matrix array of the solar-array panel.
Optionally, the sub cells are formed by cutting regular PV solar cell.
Optionally, the multiple solar-array panels are connected in parallel and coupled to operate with a panel DC/ AC inverter, to invert the DC output voltage of aid solar-array panels to AC voltage.
Optionally, the array parallelly connected solar-array panels are further connected in serial with a battery charger. Preferably, the battery charger is coupled to operate with a maximum power point tracker (MPPT) optimizer, and wherein the multiple solar-array panels are connected in parallel.
Optionally, the multiple solar-array panels are serially connected to form a string of solar-array panels, wherein the multiple strings of solar-array panels are connected in parallel, and wherein the array of multiple strings of solar-array panels are connected in parallel is further serially connected with a DC to AC inverter.
Optionally, the DC output of the matrix array of the PV solar sub cells is regulated by a MPPT optimizer, to provide maximum yield of power from the solar matrix array panel of the system. Optionally, a communication unit facilitates communication between the MPPT optimizer and a remote computerized unit.
Optionally, each of the string of solar-array panels is serially connected with a DC to AC inverter, before being parallelly interconnected.
Optionally, the DC output of the matrix array is serially connected to an inverter that inverts the DC voltage to AC voltage.
Optionally, the solar power generation system further includes a MPPT optimizer, an input/output voltage/current measurement unit and a power-calculation-processor, wherein the maximum power point (MPP) of the crisscross matrix of sub solar cells is regulated by the MPPT optimizer, based on the voltage/current measurements obtained by the measurement unit and analyzed by the power-calculation-processor. Optionally, the solar power generation system further includes a central monitoring and control sub system having a central processor, wherein the matrix array panel further includes a transmitter and a receiver, wherein the transmitter is configured to transferring the measurement data obtained from input /output voltage/current meter to a central processor; wherein the receiver is configured to receive commands from the central processor; and wherein the power-calculation-processor is configured to provide the MPPT optimizer with regulation data to thereby regulate the MPP of the crisscross matrix of sub solar cells.
Optionally, the central processor is further configured to send and/or receive data to and/or from a remote processor.
Optionally, the remote processor is selected from a group including a remote computer and a smart mobile device.
Optionally, the data is selected from a group including panel energy, power, temperature, voltage, current, time and date, a disable command and an enable command.
Optionally, the multiple solar-array panels that are MPP regulated, are serially connected to form a string of solar-array panels, and wherein the multiple strings of solar-array panels are connected in parallel.
Optionally, the multiple solar-array panels, that are MPP regulated, connected in parallel. Optionally, each of the solar-array panels is serially connected in series with a DC to AC inverter, before being interconnected in parallel.
Optionally, each of the solar-array panels is serially connected with a DC to AC inverter, and wherein the solar-array panels are connected in parallel before being serially connected with the DC to AC inverter and after being serially connected with the DC to AC inverter. Optionally, the parallel connection of the solar-array panels, before being serially connected with the DC to AC inverter, is switchable.
Optionally, the solar power generation system further includes a central monitoring and control sub system having a central processor, wherein each of the matrix array panel further includes a processor, output/input voltage/current measurement, transmitter and a receiver, wherein the transmitter is configured to transferring the
measurement data obtained from input/output voltage/current meter to a central processor; wherein the receiver is configured to receive commands from the central processor; and wherein the power-calculation-processor is configured to provide the MPPT optimizer with regulation data to thereby regulate the MPP of the crisscross matrix of sub solar cells of the matrix array panels.
Optionally, the DC output of the matrix array is connected to a DC/DC power converter.
Optionally, the DC output of the matrix array is connected to multiple DC/DC power converters.
Optionally, the DC output of each of the strings of serial-units of the matrix array is serially connected to a DC/DC power converter, and wherein the parallelly connected DC/DC power converters are serially connected to a MPPT.
Optionally, the DC output of each of the strings of serial-units of the matrix array is serially connected to a DC/DC power converter, wherein each the DC/DC power converters is serially connected to a respective MPPT.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become fully understood from the detailed description given herein below and the accompanying drawings, which are given by way of illustration and example only, and thus not limiting in any way, wherein:
Fig. 1 (prior art) is a schematic illustration of the equivalent electrical circuit of a PV cell .
Fig. 2 (prior art) is a schematic illustration of a solar cell matrix having regular PV solar cells interconnected in a crisscross configuration.
Fig. 3 (prior art) is a schematic example of a solar cell module, wherein a DC to DC voltage converter is connected to the output of the solar cell matrix shown in Fig. 2.
Fig. 4 (prior art) illustrates current-voltage characteristics of a typical solar array module, with various cell temperatures and various irradiance levels, including voltage range of maximum power point regulation zone.
Fig. 5a is a schematic illustration of an example solar cell matrix having PV cell units interconnected in a crisscross configuration, according to some embodiments of the present invention, wherein each PV cell unit consists of 3 PV sub cells.
Fig. 5b is a schematic illustration of another example solar cell matrix having PV cell units interconnected in a crisscross configuration, according to some embodiments of the present invention, wherein each PV cell unit consists of 3 PV sub cells.
Fig. 6 is a schematic illustration of another example of a solar sub cells matrix, wherein each PV cell unit consists of at least one PV sub cell, interconnected in a crisscross matrix configuration of M rows and N columns, according to some embodiments of the present invention.
Fig. 7a is a schematic illustration of an example solar cells panel, wherein the matrix of the solar sub cells of the panel is, for example with no limitations, similar to the solar cell matrix shown in Fig. 6.
Fig. 7b is a schematic illustration of an example of a solar cells panel shown in Fig. 7a, wherein two rows of sub cells are shaded, and wherein one or more bypass diodes are connected, when each diode bypasses one or more respective rows of solar cell units.
Fig. 7c is a schematic illustration of an example solar panels array (each panel, in this example, is similar to solar cell matrix panel shown in Fig. 7a), wherein the panels are connected in parallel, and wherein the solar array panels array is coupled with a panel DC/ AC inverter, to invert the DC output voltage of the solar matrix array panel to AC voltage, for example to 220V or 110V, according to embodiments of the present invention.
Fig. 7d is a schematic illustration of an example solar panels array, similar to the array of solar panels shown in Fig. 7c, but the array is serially connected to the input of a battery charger with maximum power point tracker (MPPT).
Fig. 8a is a schematic illustration of an example solar matrix array panel coupled with a power optimizer having a MPPT device, to provide maximum yield of power from the solar matrix array panel, according to embodiments of the present invention.
Fig. 8b is a schematic illustration of another example solar matrix array panel coupled with a power optimizer having a MPPT device and a communication unit, to form a monitoring and controlled solar matrix array panel, according to embodiments of the present invention.
Fig. 8c is a schematic illustration of another example solar matrix array panel coupled with a panel DC/AC inverter, to invert the DC output voltage of the solar matrix array panel to AC voltage, for example to 220V or 110V, according to embodiments of the present invention.
Fig. 8d is a schematic illustration of another example of an array of parallelly connected strings of solar panels array, as shown, with no limitations in Fig. 7c, wherein each string of solar panels array is serially coupled with a panel DC/AC inverter that is connected in parallel in their AC outputs, according to embodiments of the present invention.
Fig. 9 is a schematic illustration showing an example of a solar-array module, including an array of crisscross network of solar sub cells and a MPPT optimizer, an input/output voltage/current measurement unit, a processor for power calculations.
Fig. 10 is a schematic illustration showing an example of a solar-array module, including an array of crisscross network of solar sub cells and a MPPT optimizer, an input/output voltage/current measurement unit, a processor, a transmitter and a receiver, for transferring measurement data from a solar-array module to the general system central controller (CC) and for transferring CC commands to each solar-array module and optionally, providing information to a remote computer or a remote smart mobile device of each panel or an entire system.
Fig. 1 la is a schematic illustration showing an example solar-array system, having several strings of solar-array modules that are connected in parallel, wherein each solar-array module includes a MPPT optimizer and an array of solar cell units having "n" PV sub cells connected in a crisscross configuration.
Fig. 1 lb is a schematic illustration showing an example solar-array system, having several solar-array modules that are connected in parallel, wherein each solar-array module includes a MPPT optimizer and an array of solar cell units having "n" PV sub cells connected in a crisscross configuration.
Fig. 12a is a schematic illustration showing another example solar-array system, having several strings of solar-array panels that are connected in parallel, wherein each solar-array module includes a MPPT optimizer, communication device and an array of solar cell units having "n" PV sub cells connected in a crisscross configuration, and wherein all solar-array modules are controlled by a central monitoring and control system and transmits data to customer PC or mobile phone.
Fig. 12b is a schematic illustration showing another example of a solar-array system, having several solar-array panels that are connected in parallel, wherein each solar-array module includes a MPPT optimizer, communication device and an array of solar cell units having "n" PV sub cells connected in a crisscross configuration, and wherein all solar-array modules are controlled by a central monitoring and control system and transmits data to customer PC or mobile phone.
Fig. 13a is a schematic illustration showing an example solar-array system, having for example m * nsolar-array panels, wherein each panel includes a crisscross matrix of PV sub solar cells, and wherein the solar-array system includes a DC/ AC inverter.
Fig. 13b is a schematic illustration showing an example solar-array system, having for example "n" solar modules when each one consists of solar panel equipped by MPPT optimizer and Communication devices, wherein each panel includes a crisscross matrix of PV sub solar cells, and wherein the DC/ AC inverter is connected to each module.
Fig. 13c is a schematic illustration showing an example solar-array system, having for example "n" solar modules when each one consists of solar panel equipped by MPPT optimizer and communication devices, wherein each panel includes a crisscross matrix of PV sub solar cells, and wherein the DC/AC inverter is connected to each module. Furthermore, in this example, the solar modules are parallelly interconnected.
Fig. 13d is a schematic illustration showing an example solar-array system, having for example "n" solar modules when each one consists of a solar panel equipped by MPPT optimizer and communication device, wherein each panel includes a crisscross matrix of PV sub solar cells, and wherein the DC/AC inverter connects to each module. Furthermore, in this example, the solar modules are parallelly interconnected, wherein the connections in the parallel DC inputs are controllably switchable, according to embodiments of the present invention.
Fig. 14 is a schematic illustration of an example solar cell module, wherein a DC to DC voltage converter is connected to the output of the solar cell matrix shown in Fig. 5b, according to some embodiments of the present invention.
Fig. 15 is a schematic illustration of another example solar cell module, wherein a number of DC to DC voltage converters are connected to the output of the solar cell matrix shown in Fig. 5b, according to some embodiments of the present invention.
Fig. 16 is a schematic illustration of another example solar cell module, wherein a number of DC to DC voltage converters are connected to the output of the solar cell matrix, as shown in Fig. 5b, and a MPPT device is connected to the output of the above converters with paralleled outputs, according to some embodiments of the present invention.
Fig. 17 is a schematic illustration of another example solar cell module, wherein a number of DC to DC voltage converters are connected to the output of the solar cell matrix, as shown in Fig. 5b, and a number of MPPT devices are connected to output each one of the above converters and the outputs of MPPT devices are paralleled, according to some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown.
Reference is now made to the drawings. Fig. 2 shows a prior art schematic illustration of a solar cell matrix network 200 having regular PV solar cells 210 interconnected in a crisscross configuration. Fig. 3 (prior art) is a schematic example of a solar cell module 205, wherein a DC to DC voltage converter 250 is connected to the output of solar cell matrix 200. Such embodiments are described in '607. It should be noted that the DC to DC voltage converter 250 may be a push-pull converter, an UP converter, a forward converter, a maximum power point tracker (MPPT) device or other types of converters, or a combination thereof.
An aspect of the present invention is to provide a system that bring each solar-array module to work at the Maximum Power Point (MPP) to maximize power generation. The power produced by a solar array system is affected by the cell temperature, the load on the system and the level of irradiance. Fig. 4 depicts two graphs (110, 120) of a solar module: current-voltage characteristics at various cell temperatures graph 110 and current-voltage characteristics at various irradiance levels graph 120. In each of the graphs (110, 120), the width of the regulated zone (114, 124) may differ significantly, for example, as a function of the shading conditions. In addition, in each of the graphs (110, 120) the current remains generally steady as the voltage increases, until it drops down sharply at a certain voltage level, forming a knee-shaped curvature. At some point the knee is considered to have reached the Maximum Power Point (MPP) of the solar module. For example, at a radiance level of 1000W/m2, the MPP is denoted by point 122 (approximately 28V); and at a temperature of 25°C, the MPP is marked by point 112 (approximately 25V). Hence, if the irradiance level or the temperatures are changed, the MPP changes and the output power decreases.
Fig. 5a is a schematic illustration of an example of a solar cell matrix network 300a having serial unit 310 of PV subs cells 320 interconnected in a crisscross configuration, according to some embodiments of the present invention, wherein the combined PV area of each serial unit 310, in this example, with no limitations, is equivalent to the PV area of a regular solar cell 210 (see Fig.3). In some embodiments, a regular size PV cell 210 is cut into the desired number of sub cells with similar dimensions.
Fig. 5b is a schematic illustration of another example of a solar cell matrix network 300b having serial unit 310 of PV sub cells 320 interconnected in another crisscross configuration, according to some embodiments of the present invention, wherein the combined PV area of each serial unit310, in this example, with no limitations, is equivalent to the PV area of a regular solar cell 210. In some embodiments, a regular size PV cell 210 is cut into the desired number of sub cells with similar dimensions.
In these example matrices 300, it is shown that each regular cell (210) is subdivided into 3 (three) sub cells. It should be noted that if the total number of sub cells 320 in a matrix 300 is denoted by "«", the total number of sub cells 320 may be: 0
Documents
Application Documents
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Name
Date
1
201917033555.pdf
2019-08-20
2
201917033555-STATEMENT OF UNDERTAKING (FORM 3) [20-08-2019(online)].pdf
2019-08-20
3
201917033555-FORM 1 [20-08-2019(online)].pdf
2019-08-20
4
201917033555-DRAWINGS [20-08-2019(online)].pdf
2019-08-20
5
201917033555-DECLARATION OF INVENTORSHIP (FORM 5) [20-08-2019(online)].pdf