Method for manufacturing a solar cell string, solar cell string, processing apparatus for a solar cell string and use of such processing apparatus for a solar cell string

CN117178376BActive Publication Date: 2026-09-18FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
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Patent Information

Application Number
CN202280026970.1
Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
Priority Date
2021-03-18
Filing Date
2022-03-17
Publication Date
2026-09-18
Estimated Expiration
2042-03-17

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Benefits of technology

[0025] Another advantage of the method according to the invention is that it is suitable for both forming solar cell strings arranged side-by-side in a plane and forming shingled arrangements. Shingled arrangements of solar cells are known in themselves, i.e., solar cells are arranged in a manner similar to roof tiles, such that each solar cell slightly covers the adjacent solar cell on one side and is slightly covered by another adjacent solar cell on the other side.

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Abstract

The present invention relates to a method for manufacturing solar cell strings, wherein solar cells are arranged in a solar cell stack and electrically connected via a battery connector.
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Description

[0001] The present invention relates to a method for manufacturing solar cell strings according to claim 1 and the use of the processing equipment according to claim 13, the processing equipment being used for manufacturing solar cell strings.

[0002] The conversion of electromagnetic radiation into electrical energy using photovoltaic solar cells is typically achieved through solar cell modules containing multiple solar cells.

[0003] Such solar cell modules typically have multiple solar cell strings. A solar cell string consists of multiple solar cells that are electrically connected to each other. Typically, because individual solar cells produce only a low voltage but a high current, the solar cells in a solar cell string are connected in series.

[0004] A typical solar cell has two metal contact structures, known as electrodes. The p-electrode is conductively connected to the p-doped region of the solar cell, and the n-electrode is conductively connected to the n-doped region of the solar cell.

[0005] A solar cell string is known from US2018 / 212073A1, wherein the solar cells are connected by flexible cell connectors.

[0006] In a solar cell string, solar cells are typically connected in series using a rigid cell connector that electrically connects the metal contact structures of one solar cell to the metal contact structures of an adjacent solar cell. This conductive connection is usually intended to form a series connection, such that the n-electrode of one solar cell is electrically connected to the p-electrode of an adjacent solar cell, or vice versa.

[0007] However, these battery connectors have operational drawbacks in the manufacture of solar cells. Furthermore, the mechanical loads on the solar cell strings, particularly the mechanical stress caused by thermal loads, can increase the contact resistance between the battery connector and the solar cell, even leading to contact interruption when the battery connector becomes loose. In addition, these rigid battery connectors exert thermomechanical stress on the cells, which may cause them to crack.

[0008] Therefore, there is a need for a cost-effective yet robust solar cell string and a method for manufacturing such a string. Furthermore, due to limitations on the thickness of the cell connectors and the bending radius, typical cell connectors require a minimum spacing between adjacent solar cells. There is a need to reduce this minimum spacing.

[0009] Therefore, the object of the present invention is to provide a method for manufacturing solar cell strings and to provide such solar cell strings.

[0010] The objective is achieved by the method for manufacturing solar cell strings according to claim 1, the solar cell strings according to claim 12, the processing equipment for solar cell strings according to claim 13, and performing the method according to the invention using the processing equipment.

[0011] Advantageous embodiments are given in the dependent claims.

[0012] The method for manufacturing solar cell strings according to claim 1 of the present invention comprises method steps A and B: In step A of the method, a solar cell stack with at least five solar cells is provided, each solar cell having a front and a back side, the solar cells being arranged in an overlapping manner such that in each solar cell, the edge of the contact area of ​​the front side of the solar cell and the edge of the contact area of ​​the back side of the solar cell are not covered by adjacent solar cells.

[0013] In step B of the method, a conductive connection is formed between the solar cells, wherein: A conductive first connecting element is disposed on the solar cell stack to form a conductive connection, such that the first connecting element on the first side of the solar cell stack is conductively connected to the contact area of ​​the solar cell on the first side. The first connecting element is divided into a first set of battery connectors, such that pairs of adjacent solar cells on the first side of the solar cell stack are electrically connected to each other through the first set of battery connectors. A conductive second connecting element is disposed on the solar cell stack to form a conductive connection, such that the second connecting element on the second side of the solar cell stack is conductively connected to the contact area of ​​the solar cell on the second side. The second connecting element divides the second set of battery connectors so that pairs of adjacent solar cells on the second side of the solar cell stack are electrically connected to each other through the second set of battery connectors.

[0014] The method according to the invention can form solar cell strings in a particularly cost-effective manner because only two connecting elements are applied to the solar cell stack, which are separated into battery connectors only after being electrically connected to the solar cells, and the battery connectors electrically connect two adjacent solar cells in subsequent solar cell strings to each other.

[0015] Advantageously, the electrical interconnection of the solar cells in the solar cell string is performed in a manner known per se, wherein the front side of a solar cell in the solar cell string is conductively connected to the back side of an adjacent solar cell. As mentioned above, a typical solar cell has metal electrodes on both its front and back sides. Advantageously, the battery connector can conductively connect the metal electrodes on the front side of a solar cell to the metal electrodes on the back side of an adjacent solar cell, or vice versa.

[0016] In order to form a connection between the front and back sides of two adjacent solar cells, in step A of the method, the solar cells are stacked together with their front sides facing each other or their back sides facing each other, and it is particularly advantageous to alternate between front sides facing each other and back sides facing each other.

[0017] Thus, in this advantageous embodiment, starting with the bottom solar cell of the solar cell stack, the solar cells are arranged in ascending order with their front faces facing each other and their back faces facing each other, or conversely, they are arranged in alternating order, starting with their back faces facing each other, followed by their front faces facing each other, and so on.

[0018] This ensures that the battery connector, which electrically connects two stacked solar cells on one side of the solar cell stack, always electrically connects the front of one solar cell to the back of the other.

[0019] Within the scope of this invention, a first connecting element is disposed on a first side of the solar cell stack, and a second connecting element is disposed on a second side of the solar cell stack, and the two connecting elements are subsequently separated into a first battery connector and a second set of battery connectors.

[0020] Advantageously, the first connecting element is divided into a first set of battery connectors before the second connecting element is installed. This allows the fabrication of the first side of the solar cell stack to be completed before the fabrication of the second side.

[0021] Advantageously, in step B of the method, the solar cell stack is flipped between setting the first connecting element and setting the second connecting element. This has the advantage that processing can begin from a constant spatial orientation. Particularly advantageously, the arrangement and division of the first connecting element are first performed as described above, followed by flipping the solar cell stack, and then the second connecting element is arranged and divided on the second side of the solar cell stack.

[0022] In an advantageous embodiment, in method step B, in addition to splitting the first and second connecting elements, excess material of the first and second connecting elements is also removed. Particularly advantageously, the excess material is separated by a laser beam.

[0023] After completing step B of the method, a solar cell stack with solar cells is formed, wherein two solar cells stacked on top of each other are electrically connected to each other through a first set and a second set of battery connectors.

[0024] Following step B, the solar cells are arranged in a stacked array by rotational movement of the solar cells, wherein the solar cells are arranged side by side or in a shingled layout.

[0025] Another advantage of the method according to the invention is that it is suitable for both forming solar cell strings arranged side-by-side in a plane and forming shingled arrangements. Shingled arrangements of solar cells are known in themselves, i.e., solar cells are arranged in a manner similar to roof tiles, such that each solar cell slightly covers the adjacent solar cell on one side and is slightly covered by another adjacent solar cell on the other side.

[0026] Within the scope of this invention, in method step B, the conductive connection between the first and second connecting elements and the solar cell is performed in a manner known per se, particularly preferably through a thermal effect. Within the scope of this invention, the conductive connection is achieved by welding, and particularly by direct contact with a heated welding element. Forming a conductive connection by adhesive, particularly by a conductive adhesive, is also within the scope of this invention.

[0027] Particularly advantageously, in method step B, the conductive connection between the first and second connecting elements and the solar cell is formed by a laser beam. It is known per se that a thermal effect is generated by the laser beam to form a conductive connection between the two metal surfaces. In this advantageous embodiment, known precision machining units can thus be used, particularly precision machining units equipped with a laser and a laser deflection unit.

[0028] Therefore, it is particularly advantageous that, in step B, the splitting of the first and second connecting elements and the conductive connection between the first and second connecting elements and the solar cell are performed using a laser beam. This allows both process steps to be completed in a low-cost and rapid manner.

[0029] To enable conductive connection of the solar cell strings in the solar cell module to other connecting elements, particularly other solar cell strings, it is advantageous to, in step A of the method, provide end connectors on the outside of the solar cells at at least two ends of the solar cell stack, and these end connectors are conductively connected to the external solar cells. Each of the two external solar cells is thus conductively connected to an end connector.

[0030] If the solar cell stack has an odd number of solar cells, then in method step B, one end connector is preferably electrically connected to the first connecting element, while the other end connector is electrically connected to the second connecting element.

[0031] If the solar cell stack has an even number of solar cells, the two end connectors are preferably electrically connected to the same connecting element, and particularly preferably to the first connecting element.

[0032] Thus, in steps A and B of the method, not only is the electrical interconnection of each solar cell in the solar cell string realized, but also the electrical interconnection of the first solar cell of the solar cell string with one end connector and the electrical interconnection of the last solar cell of the solar cell string with another end connector are realized in a process-economical manner.

[0033] The end connector is preferably constructed as a metal element, particularly preferably as an elongated metal element, the length of which preferably corresponds to the side length of the solar cell extending transversely to the longitudinal extension of the solar cell string.

[0034] The first and second connecting elements are preferably configured as flexible connecting elements. This reduces the mechanical stress on the contact surface between the battery connector and the solar cell, and allows for a smaller spacing between the solar cells in the solar cell string compared to a rigid battery connector.

[0035] The thickness of the first and second connecting elements and the battery connector is preferably less than 100µm, particularly preferably less than 50µm, and even more preferably less than 20µm. The thickness is preferably in the range of 5µm to 30µm.

[0036] Within the scope of this invention, the connecting element may be configured as a coated connecting element, particularly a metal coated connecting element, preferably configured as a metal coated foil.

[0037] A particularly advantageous embodiment is that the first and second connecting elements are constructed as metal foils, preferably single-layer metal foils. This allows for the inexpensive production of cost-effective components for use as battery connectors compared to coated or multi-layer foils.

[0038] As previously described, a typical solar cell has conductive electrodes on both the front and back sides, at least in the contact areas. Therefore, it is advantageous to provide such a solar cell with conductive electrodes on both the front and back sides, at least in the contact areas, in method step A, and in method step B, to electrically connect the first and second connecting elements to the electrodes of the solar cell.

[0039] As mentioned at the beginning, according to the invention, it is advantageous to connect the solar cells in a solar cell string in series. Therefore, in method step B, the solar cells are electrically connected in series via first and second sets of battery connectors.

[0040] Furthermore, the method according to the invention has the advantage that the battery connector only slightly covers the solar cell at least on the front side of the solar cell along the extension direction of the solar cell string. The area of ​​the battery connector covering the solar cell on the front side, particularly the electrodes disposed on the front side of the solar cell, therefore preferably has a width of less than 1000µm, particularly less than 500µm, and preferably less than 300µm. This width extends perpendicular to the edge of the solar cell where the battery connector is disposed and parallel to the extension direction of the solar cell string. The width of the contact area is preferably greater than 100µm, more preferably greater than 200µm, and particularly greater than 250µm, in order to form a mechanically stable connection between the battery connector and the solar cell.

[0041] Furthermore, the method according to the invention enables the solar cells to overlap over a greater length perpendicular to the extension direction of the solar cell, thereby forming a mechanically well-attached contact and an electrical contact with low contact resistance.

[0042] Advantageously, the battery connector covering area on the front side of the solar cell has a length greater than the side length of the solar cell and thus greater than 80%, preferably greater than 90%, and particularly preferably greater than 95% of the width of the solar cell string. Thus, the length of the contact area extends parallel to the edge where the battery connector is located and perpendicular to the extension direction of the solar cell string.

[0043] A solar cell string manufactured by means of the method according to the invention or an advantageous improvement thereof, the solar cell string having at least five solar cells, each solar cell having an electrode on a front side and an electrode on a back side, the solar cells being arranged in a row along the longitudinal direction of the solar cell string and electrically connected in series, wherein the electrode on the front side of the solar cell is electrically connected to the electrode on the back side of the adjacent solar cell via a battery connector. The battery connector is configured as a flexible battery connector, and each battery connector has at least one, preferably exactly one, fold, wherein portions of the battery connector are arranged in parallel overlap, the opening of the fold extending perpendicular to the longitudinal direction of the solar cell string, and the opening sides of the fold alternating along the longitudinal direction of the solar cell string.

[0044] In such a solar cell string, adjacent solar cell pairs thus alternately have mutually facing openings of the folded portions of the battery connectors and mutually opposing openings of the folded portions of the battery connectors. This advantageous embodiment is produced by a method according to the invention, wherein the battery connectors are arranged on a solar cell stack, and then the solar cell stack is unfolded to form a solar cell string. Here, within the scope of the invention, the solar cell string according to the invention is constructed having solar cells arranged adjacent to each other in a plane or having solar cells arranged in a shingled layout.

[0045] The processing equipment for solar cell strings makes the implementation of the method according to the invention particularly simple and thus error-free and cost-effective. The processing equipment has multiple support surfaces for multiple solar cells, which are arranged in a stepped manner and parallel to each other. This allows for the simple formation of a solar cell stack to provide a solar cell stack according to step A of the method.

[0046] The step formed by the support surface preferably has a step height approximately equivalent to the total thickness of the solar cell, and the step height is preferably less than 50%, particularly less than 30%, of the total thickness of the solar cell. The width of the support surface is preferably less than the width of the solar cell placed on the support surface, and particularly preferably the width of the support surface of the contact device is equivalent to the width of the solar cell surface after deducting the contact area.

[0047] This enables the formation of a solar cell stack with overlapping solar cells according to step A of the method according to the invention, when the solar cells are placed on the support surface.

[0048] Therefore, according to the invention, it is advantageous to use a processing device to perform the method according to the invention, especially its preferred embodiment, in which each solar cell of the solar cell stack is placed in a portion of the support surface of the processing device in step A of the method, and the width of the solar cell is greater than the width of the support surface.

[0049] This invention is not limited to manufacturing solar cell strings with five solar cells. More specifically within the scope of this invention are solar cell stacks having a number of solar cells ranging from five to twenty, and all the solar cells in the stack being electrically interconnected, particularly in series, via a first and second set of battery connectors according to the method according to the invention, particularly according to an advantageous embodiment of the method. In particular, the solar cell stack preferably has more than five, preferably more than eight, and particularly preferably more than ten solar cells.

[0050] Further advantageous features and embodiments are explained below with reference to the accompanying drawings and examples. It can be seen from this that: Figure 1 and Figure 2 Partial steps of method step B according to an embodiment of the method according to the present invention are shown; Figure 3 A side view and a top view of a first embodiment of a solar cell string manufactured by means of the method according to the invention are shown; Figure 4 A side view and a top view of a second embodiment of a solar cell string manufactured by means of the method according to the invention are shown; Figure 5 A cross-sectional view of one embodiment of the processing equipment is shown; and Figure 6 It shows Figure 5 The top view of the processing equipment shown.

[0051] All accompanying figures are shown as schematic diagrams and are not to scale. The same reference numerals in the figures indicate the same or equivalent elements.

[0052] exist Figure 1 and 2 The diagram shows a portion of method step B of an embodiment of the method according to the present invention.

[0053] According to Figure 1 The illustration shows that step A of method has been performed, in which a solar cell stack with five solar cells 1 is provided. Each solar cell 1 has a front and a back side, and the solar cells are arranged in an overlapping manner such that in each solar cell, the edge of the contact area 2 on the front side and the edge of the contact area 3 on the back side are not covered by the adjacent solar cells.

[0054] like Figure 1 As shown, the solar cells 1 in the solar cell stack are thus arranged parallel to each other and form a stepped structure due to only partial overlap.

[0055] In step B of the method, a conductive first connecting element 4 is provided, which is designed as a metal foil.

[0056] The first connecting element 4 generally follows Figure 1 The stepped shape on the first side of the solar cell stack on the left side, and through... Figure 1 The laser beam, indicated by solid arrow 6, achieves conductive connection between the first connecting element 4 on the first side of the solar cell stack and the contact areas 2 and 3 of the solar cell 1 on the first side of the solar cell stack through the thermal effect generated by the laser beam 6.

[0057] like Figure 1As shown, in method step A, a first end connector 7 is additionally disposed on the topmost solar cell 1 of the solar cell stack. The first end connector 7 and Figure 1 The uppermost solar cell 1 has its left edge spaced apart, thus continuing the stepped shape through the first end connector 7. In method step B, a conductive connection is formed between the first end connector 7 and the first connecting element 4 by thermal action using a laser beam 6, thereby placing the first connecting element 4 on the first end connector 7.

[0058] In another sub-step of method step B, the first connecting element 4 is separated using a first laser beam 9 to split the first connecting element 4 into a first set of battery connectors 11. The first laser beam 9 used to separate the first connecting element 4 is shown in dashed lines.

[0059] Through this distribution of the first connecting element 4 and the resulting battery connectors 11, pairs of adjacent solar cells 1 on the first side of the solar cell stack are electrically connected to each other. In this example, this is the first pair consisting of the bottommost solar cells on the first and second solar cells, and the second pair consisting of the third and fourth solar cells. Furthermore, the topmost fifth solar cell is electrically connected to the first end connector 7 via the first set of battery connectors 11.

[0060] The first laser beam 9 used to separate the first connecting element 4 is sufficient to form the first set of battery connectors. However, excess material remains in the first connecting element 4. Therefore, the second laser beam 10 separates the excess material in the first connecting element 4.

[0061] Next, the solar cell stack will be flipped around a point perpendicular to the ground. Figure 1 The axis of the drawing plane is rotated 180°.

[0062] The resulting configuration Figure 2 As shown, in another sub-step of method step B, a second connecting element 5, also designed as a metal foil, is disposed on the second side of the solar cell stack. The second side of the solar cell stack is opposite to the first side, and through the aforementioned rotation, in Figure 2 The second side of the solar cell stack is located on the left side, opposite to it. Figure 1 In the middle, the first side of the solar cell stack is located on the left side.

[0063] As already described with respect to the first connecting element 4, the conductive connection between the second connecting element and the solar cell 1 is also achieved in the second connecting element through the laser beam 6 and the resulting heat. Similarly, after the solar cell stack is flipped, the second end connector 8 is positioned on the uppermost solar cell 1 after the solar cell stack is flipped. The second end connector 8 is also conductively connected to the second connecting element 5 via the laser beam 6.

[0064] Similarly, the separation of the second connecting element 5 is achieved by using the first laser beam 9, so as to form the battery connector 12 in the second set of battery connectors by distributing the second connecting element 5.

[0065] Through the battery connector 12 of the second set of battery connectors, the second side of the solar cell stack ( Figure 2 The paired adjacent solar cells 1 (on the left side of the image) are thus electrically connected to each other. In this example, when numbering from the bottom up, as shown... Figure 2 As shown, it consists of a pair of the bottommost first solar cell and the adjacent second solar cell, and a pair of the third and fourth solar cells numbered from the bottom. Similarly, the topmost solar cell 1 is electrically connected to the second end connector 8 via the battery connector 12 in the second set of battery connectors.

[0066] For the second connecting element, a separation step is also performed using the second laser beam 10 to remove excess material from the second connecting element 5. According to... Figure 2 In the illustration, the excess material of the first connecting element 4 has been removed, leaving only the battery connector 11 in the first set of battery connectors.

[0067] Since the front and back sides of the solar cells 1 in the solar cell stack are arranged alternately, each battery connector 11 of the first group and the battery connector 12 of the second group respectively connect the front side of a solar cell to the back side of the solar cell located above or below it.

[0068] Each solar cell has an identical design and has a metal front electrode (not shown) on the front contact area and a metal contact electrode on the back contact area. The first set of battery connectors 11 and the second set of battery connectors 12 are electrically connected to the solar cells via the aforementioned electrodes.

[0069] For current solar cells, the electrode on the front side is designed as an n-electrode, and the electrode on the back side is designed as a p-electrode, thus forming an electrical series connection in the solar cell.

[0070] By rotating the solar cells, the solar cell stack is now flipped and unfolded (Aufklappen), thus positioning the solar cells within the solar cell string and extending them along the longitudinal direction of the string. For example... Figure 3 As shown: exist Figure 3 Figure a) shows a side view of the solar cell string, which is unfolded after the conductive connection and disconnection steps are performed by laser beams 6, 9, and 10. Figure 2 The solar cell stack shown in the image was formed later.

[0071] exist Figure 3 In the first embodiment of the solar cell string according to the present invention, the lengths of the first set of battery connectors 11 and the second set of battery connectors 12 are selected in a manner that forms a shingled layout. Figure 3 As shown in a), each solar cell covers an adjacent solar cell on the right side of the contact area and is covered by an adjacent solar cell on the left side of the contact area, thus forming a shingled layout known per se. The edge solar cells are electrically connected to the aforementioned end connectors 7 and 8 at their outer edges, respectively.

[0072] For clarity, the extension direction 13 of the solar cell string is indicated by arrows. Solar cells 1 are arranged in rows along the extension direction 13.

[0073] The first set of battery connectors 11 and the second set of battery connectors 12 each have a folded portion, wherein partial areas of the battery connectors are stacked parallel to each other, the opening of the folded portion extends perpendicular to the longitudinal extension direction 13 of the solar cell string, and the opening sides of the folded portion are alternately arranged along the longitudinal extension of the solar cell string. For example, in Figure 3 As shown in a), starting with the solar cell on the left, the folded portion of the battery connector between the first and second solar cells is open on the right, while the folded portion of the battery connector between the second and third solar cells is open on the left. Thus, the opening sides of the folded portions alternate left and right along the longitudinal extension direction 13 of the solar cell string.

[0074] exist Figure 3 Figure b) shows a top view of the solar cell string. It can be seen here that solar cell 1 has a known contact structure on its front side, namely the so-called contact fingers, which extend parallel and are shown by black lines.

[0075] Due to this shingled layout, in a top view, the cell connectors between the solar cells are individually covered by the solar cells due to their overlapping arrangement.

[0076] exist Figure 4A second embodiment of the solar cell string according to the present invention is shown. To avoid repetition, only the embodiment described below is relevant to the one in [the present invention]. Figure 3 The main differences are shown in the first embodiment.

[0077] exist Figure 4 The solar cell strings shown are also using Figure 1 and Figure 2 It is manufactured using the steps described in the method. (And...) Figure 3 The embodiment shown is different; the first set of battery connectors 11 and the second set of battery connectors 12 have a longer length, thereby achieving a non-overlapping arrangement of the individual solar cells 1, so that these solar cells form a plane along the extension direction 13 of the solar cell string.

[0078] The first set of battery connectors 11 and the second set of battery connectors 12 extend from the contact area on the front side of the solar cell 11 between two adjacent solar cells to the contact area on the back side of the adjacent solar cell. These solar cells 1 and Figure 3 The solar cell 1 described in the first embodiment also has electrodes on its front and back sides, which are electrically connected to the battery connector, thereby forming an electrical series connection in such a solar cell string.

[0079] like Figure 4 As shown in a), in this arrangement, each battery connector also has a fold, and in this arrangement, the opening direction of the fold of the battery connector is also alternately arranged along the extension direction 13 of the solar cell string.

[0080] Figure 4 Figure b) shows a top view of the solar cell string according to the second embodiment. Since there is no shingled layout here, the cell connectors are partially visible in the top view.

[0081] exist Figure 5 An embodiment of the processing apparatus 14 according to the present invention is shown. The processing apparatus has multiple stepped support surfaces, on which five solar cells 1 are placed in this example. The support surfaces are arranged in a stepped manner and are parallel to each other, such that the solar cells are stacked parallel to each other, wherein, in each solar cell, the edges of the contact areas on the front and back sides of the solar cell 1 are not covered by adjacent solar cells 1.

[0082] The processing equipment 14 has multiple holes 15 to generate negative pressure by a pump, thereby enabling the solar cell 1 to be stably mounted on the processing equipment 14 using negative pressure.

[0083] exist Figure 6 It shows Figure 5 A top view of the processing equipment shown. Figure 6 As shown, a plurality of holes 15 are provided around the support surface of the solar cell 1 on the edge of the processing equipment 14, the holes being indicated by circles. The holes are exemplary labeled with reference numeral 15 in the upper left corner. When the conductive connection element is provided in the form of a metal foil, the metal foil is placed from above... Figure 5 On the solar cell stack, the metal foil completely covers the solar cells and also covers... Figure 6 The circumferential edge of the processing equipment 14 shown in the figure is such that the metal foil is pressed onto the processing equipment 14 and the solar cell 1 by a negative pressure generated by a pump through the hole 15 shown in the circle, thereby forming a battery connector.

[0084] Subsequently, conductive connections are formed, and the connecting elements, i.e., metal foils, are cut as described above.

[0085] List of reference numerals 1 solar cell 2. Front contact area 3. Contact area on the back 4 First connecting element 5 Second connecting element 6. Laser beams used to achieve conductive connections 7 First end connector 8 Second end connector 9. First laser beam used for separation 10. Second laser beam used for separation 11 Battery connectors in the first group of battery connectors 12. Battery connector in the second group of battery connectors 13 Extension Directions 14 Processing Equipment 15 holes

Claims

1. A method for manufacturing solar cell strings, comprising the following steps: A. A solar cell stack having at least five solar cells (1), each solar cell (1) having a front and a back side, the solar cells (1) being arranged in an overlapping manner such that, in each solar cell (1), the edge of the contact area (2) of the front side of the solar cell (1) and the edge of the contact area (3) of the back side of the solar cell (1) are not covered by adjacent solar cells (1). B. A conductive connection is formed between the solar cells (1), wherein: - A conductive first connecting element (4) is provided on the solar cell stack and a conductive connection is formed, such that the first connecting element (4) on the first side of the solar cell stack is conductively connected to the contact area of ​​the first side of the solar cell; - Divide the first connecting element (4) into a first set of battery connectors (11) so that pairs of adjacent solar cells (1) on the first side of the solar cell stack are electrically connected to each other through the first set of battery connectors (11). - A conductive second connecting element (5) is provided on the solar cell stack and a conductive connection is formed, such that the second connecting element (5) on the second side of the solar cell stack is conductively connected to the contact area on the second side of the solar cell; - Divide the second connecting element (5) into a second set of battery connectors (12) such that pairs of adjacent solar cells (1) on the second side of the solar cell stack are electrically connected to each other through the second set of battery connectors (12). In step A of the method, the solar cells (1) are stacked and arranged with their front sides facing each other or their back sides facing each other. Following step B, the solar cells (1) are arranged in a stacked configuration by rotational movement, wherein the solar cells (1) are arranged adjacent to each other or in a shingled layout. In step B of the method, the solar cell (1) is electrically connected in series via first and second sets of battery connectors (11, 12).

2. The method according to claim 1, characterized in that, In step A of the method, the solar cells (1) are arranged alternately with their front faces facing each other and their back faces facing each other.

3. The method according to any one of the preceding claims, characterized in that, In step B of the method, the solar cell stack is flipped between setting the first connecting element (4) and setting the second connecting element (5).

4. The method according to any one of the preceding claims, characterized in that, In step B of the method, in addition to splitting the first and second connecting elements (4, 5), excess material of the first and second connecting elements (4, 5) is removed.

5. The method according to any one of the preceding claims, characterized in that, In step B of the method, in addition to splitting the first and second connecting elements (4, 5), excess material is separated by a laser beam to remove excess material from the first and second connecting elements (4, 5).

6. The method according to any one of the preceding claims, characterized in that, In step B of the method, a conductive connection between the first and second connecting elements (4, 5) and the solar cell (1) is formed by a laser beam (6).

7. The method according to any one of the preceding claims, characterized in that, In method step B, the division of the first and second connecting elements (4, 5) is performed by laser beams (9, 10).

8. The method according to any one of the preceding claims, characterized in that, In step A of the method, end connectors (7, 8) are respectively provided on the outside of the solar cells (1) at at least two ends of the solar cell stack, and the end connectors are electrically connected to the external solar cells (1).

9. The method according to any one of the preceding claims, characterized in that, The first and second connecting elements (4, 5) are configured as flexible connecting elements.

10. The method according to any one of the preceding claims, characterized in that, The first and second connecting elements (4, 5) are configured as foils.

11. The method according to any one of the preceding claims, characterized in that, The first and second connecting elements (4, 5) are configured as metal foils.

12. The method according to any one of the preceding claims, characterized in that, Each solar cell (1) has conductive electrodes on the front and back sides, at least in the contact areas (2, 3), and in step B of the method, the first and second connecting elements (4, 5) are conductively connected to the electrodes of the solar cell (1).

13. The purpose of the processing equipment, said processing equipment having multiple support surfaces for multiple solar cells (1), wherein, The support surfaces are arranged in a stepped manner and are parallel to each other. The processing equipment is used to perform the method according to any one of claims 1 to 12, wherein, in step A of the method, each solar cell (1) of the solar cell stack is placed on a portion of the support surface of the processing equipment (14), and the width of the solar cell (1) is greater than the width of the support surface.

Citation Information

Patent Citations

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