Back-Contact PV Module Assembly to Prevent Cell Warping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Back-contact photovoltaic cells face warping and cracking issues due to single-side welding stress, which affects yield and manufacturing costs, as conventional solder strip welding on the back side does not cancel out stress effectively.
Innovation Solution
A method for manufacturing photovoltaic modules involves laying a front plate with a first adhesive layer, pre-curing it between the plate and cells, forming cell strings with solder strips, and then applying a second adhesive layer and back plate, curing it to prevent warping and stress-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-side welding of solder strips is used on back-contact cells, then manufacturing process is simplified, but cell warping and cracking occur due to stress
Solution Approach 1:
The adhesive layer is applied and cured on the front side of the cell before the solder strip welding process. This preliminary action provides stress compensation that prevents warping and cracking during subsequent single-side welding operations on the back side.
Solution Approach 2:
An adhesive layer is introduced as an intermediary element between the cell structure and the welding process. This adhesive layer acts as a stress buffer that compensates for the thermal and mechanical stress generated during single-side solder strip welding, preventing cell damage while maintaining manufacturing simplicity.
2Reliability
If adhesive layer is applied before welding, then cell warping and cracking are prevented, but manufacturing process complexity increases
Solution Approach 1:
The adhesive layer application process is merged with the existing front side processing steps. The adhesive is applied and cured during the same manufacturing sequence as other front side operations, before the cells are flipped for back side welding, thereby integrating the stress compensation function without adding separate process steps.
Solution Approach 2:
The curing parameters of the adhesive layer (temperature, time, humidity) are optimized to match the existing manufacturing process parameters. By adjusting the adhesive curing conditions to align with standard production parameters, the process complexity is minimized while maintaining effective stress compensation.
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 method prevents cell warping and cracking, improving yield and reducing manufacturing costs by ensuring even stress distribution and secure bonding throughout the module.
Implementation Method 1
pre-curing the first adhesive layer between the front plate and the plurality of cells
Implementation Method 2
curing the second adhesive layer between the back plate and the plurality of cell strings
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for manufacturing a photovoltaic module and a photovoltaic module are provided. The method includes: laying a front plate, a first adhesive layer on the front plate, and a plurality of cells on the first adhesive layer, and pre-curing the first adhesive layer between the front plate and the plurality of cells; forming a plurality of cell strings by connecting the plurality of cells through a plurality of solder strips after the first adhesive layer is pre-cured; and laying a second adhesive layer on the plurality of cell strings, laying a back plate on the second adhesive layer, and curing the second adhesive layer between the back plate and the plurality of cell strings, to form the photovoltaic module.