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Significant improvements in module performance are possible via implementation of multi-wire electrodes. This is economically sound as long as the mechanical yield of the production is maintained. While flat ribbons have a relatively large contact area to exert forces onto the solar cell, wires with round cross section reduce this contact area considerably – in theory to an infinitively thin line. Therefore, the local stresses induced by the electrodes might increase to a point that mechanical production yields suffer unacceptably.
In this paper, we assess this issue by an analytical mechanical model as well as experiments with an encapsulant-free N.I.C.E. test setup. From these, we can derive estimations for the relationship between lay-up accuracy and expected breakage losses. This paves the way for cost-optimized choices of handling equipment in industrial N.I.C.E.-wire production lines.
As PV enters the terawatt era, reliability, sustainability and low carbon footprint of solar modules are key requirements. The N.I.C.E.TM technology from Apollon Solar is a good candidate for significant improvements in these areas. As the second-generation pilot line is now functional with IEC certification underway, we present a holistic assessment of N.I.C.E.TM technology compared with conventional module technology with encapsulant. This includes electrical performance and cost/consumables, reliability, and degradation mechanisms as well as sustainability aspects. In addition, the new generation of N.I.C.E.-wire modules are presented that use thin round Cu wires instead of flat ribbons for interconnection. This candidate technology for an alternative to the Smart Wire Connection Technology (SWCT) is investigated experimentally as well as via numerical simulations.