Back-Contact PV Cell Interconnection via Insulated Conductive Threads
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Solution Overview
Problem
Existing methods for electrically connecting contact areas of photovoltaic cells, particularly back-contact cells, are inflexible and require multiple process steps, often necessitating insulating layers that can lead to contamination and shadowing losses, and lack the ability to easily adapt to different cell designs.
Innovation Solution
A method using an electrical connector with an electrically conductive core and an insulating enveloping part, where the insulating threads wrap around the core, leaving it partially uncovered, allowing for flexible positioning and connection by bridging gaps with conductive material, eliminating the need for pre-made openings and insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is provided on the rear surface of the cell with openings at contact areas, then electrical insulation is achieved to prevent short-circuiting, but the process complexity increases and flexibility decreases
Solution Approach 1:
The patent extracts the insulating function from a separate insulating layer and integrates it into the connector itself through the insulating coating on the conductive core. This eliminates the need for a dedicated insulating layer on the cell surface, reducing process steps while maintaining electrical insulation reliability.
Solution Approach 2:
The connector is designed to perform multiple functions simultaneously: it provides electrical connection through the conductive core and electrical insulation through the insulating coating. This multi-functionality eliminates the need for separate insulating components and reduces overall system complexity.
2Ease of manufacture
If pre-made openings are provided in the insulating material according to terminal region spacing, then electrical connection is simplified, but adaptability to different cell designs is reduced
Solution Approach 1:
The patent makes the connector adaptable to different cell designs by allowing the spacing and positioning of uncovered conductive core sections to be adjusted according to the specific terminal region configuration. This dynamic adaptability enables the same connector design to work with various cell types without requiring pre-configured openings.
Solution Approach 2:
The insulating coating is applied selectively, leaving certain sections of the conductive core uncovered at specific locations corresponding to contact areas. This local variation in insulation provides both electrical insulation where needed and electrical connection where required, while maintaining adaptability to different cell designs.
3Reliability
If metal connectors are soldered to contact areas to extract current, then electrical connection is established, but shadowing losses occur on the cell surface
Solution Approach 1:
The patent uses a thin insulating coating on the conductive core that allows the connector to make contact with the contact areas without requiring large metal surfaces. This minimizes the shadowing effect while maintaining reliable electrical connection through the conductive core at the uncovered sections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces process steps, enhances flexibility in accommodating different cell designs, prevents short-circuits, and allows for efficient electrical connection without the need for insulating layers, enabling the same connector to be used across various cell configurations.
Implementation Method 1
By melting the electrically conductive material at selected locations, the electrically conductive material may flow through mesh openings of the electrically insulating woven material to contact the plurality of contact areas
Implementation Method 2
positioning on a surface of the photovoltaic cell an electrically insulating woven material. An electrically conductive material is provided over the electrically insulating woven material
Implementation Method 3
By melting the electrically conductive material at selected locations
Data Source
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AI summary
A method is provided for electrically connecting a plurality of contact areas located on a surface of a photovoltaic cell, the method comprising: positioning on the surface of the photovoltaic cell an electrical connector, thereby covering the plurality of contact areas with the electrical connector, and electrically connecting the electrical connector to the plurality of contact areas, wherein the electrical connector comprises an electrically conductive core and an electrically insulating enveloping part, the enveloping part comprising electrically insulating threads enveloping the electrically conductive core and leaving the electrically conductive core partially uncovered. The electrical connection may for example be established by soldering or by means of a conductive adhesive. A method is provided for electrically connecting back-contact cells within a photovoltaic module using such electrical connectors.