Back-Contact Rollable Solar Module Assembly Without Front-Side Shading
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Solution Overview
Problem
The existing flexible solar cell modules face challenges due to the small size of cell pieces requiring high precision in attaching protection layers, electrode welding difficulties, and shading effects from interconnected bars, which limit design and efficiency.
Innovation Solution
A flexible and rollable back-contact solar cell module is developed, allowing infinite extension with large cell blocks connected by a flexible interconnected bar in both horizontal and vertical directions, with electrodes on the back side to avoid shading and facilitate welding, and a pre-cutting process with an adhesive layer for easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If small cell pieces are used to form flexible solar modules, then flexibility is improved, but manufacturing precision requirements increase significantly
Solution Approach 1:
The solar cell is divided into positive and negative electrode regions on the back side, with each region containing multiple electrode groups. This segmentation allows for modular assembly while maintaining flexibility, as each segment can be independently processed and attached without requiring high precision across the entire cell surface.
Solution Approach 2:
The patent moves all electrodes to the back side of the cell, transitioning from a traditional front-and-back electrode configuration to a purely back-contact design. This dimensional reorganization eliminates the need for precise front-side electrode alignment during assembly, significantly reducing manufacturing precision requirements while maintaining cell flexibility.
2Reliability
If interconnected bars are welded on the front surface, then electrical connection is achieved, but shading effect increases reducing power generation efficiency
Solution Approach 1:
The patent inverts the traditional electrode placement by moving all metal contacts and interconnected bars to the back side of the cell. This inversion ensures that no conductive elements are present on the light-receiving front surface, completely eliminating the shading effect while maintaining reliable electrical connections through the back-contact configuration.
3Adaptability or versatility
If small cell pieces are cut and assembled, then flexibility is improved, but process complexity increases due to flipping and repositioning
Solution Approach 1:
The patent extracts the electrodes from the front surface and consolidates them entirely on the back side. This extraction simplifies the assembly process by eliminating the need to flip cells during assembly - all electrical connections can be made from the back side only, reducing process complexity while maintaining the flexibility benefits of small cell pieces.
4Productivity
If back-contact design is used, then light utilization is improved, but electrode welding accessibility becomes more difficult
Solution Approach 1:
The back side of the cell is designed to serve multiple functions: it houses both the positive and negative electrodes, provides the welding surface for electrical connections, and acts as the structural support for the entire cell. This multi-functional design maintains excellent light utilization while ensuring that all electrode welding operations can be performed from the back side without requiring front-side access.
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 solution enables flexible and efficient assembly, improved light utilization, and the ability to design solar cell modules with varying current and voltage requirements, overcoming precision and shading issues while enhancing processing convenience.
Implementation Method 1
a protective layer is attached to a surface of a light-receiving side by using an adhesive layer
Data Source
AI summary
A flexible and rollable back-contact solar cell module, wherein a length of it can be extended infinitely and the back-contact solar cell module includes a plurality of large cell blocks connected in series or in parallel. The large cell block includes a plurality of small cell strings connected in series or in parallel. The small cell string includes a plurality of small square cell pieces connected in series or in parallel. The series-connection or the parallel-connection between the large cell blocks, the small cell strings, or the small square cell pieces is achieved by welding a flexible interconnected bar in the horizontal or vertical direction. Electrodes of the small square cell pieces are all on a back side and the small square cell pieces are formed by cutting a back-contact solar cell. A protective layer is attached to a surface of a light-receiving side by using an adhesive layer.