Back-Contact Solar Cell Assembly Protrusion Lamination
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Solution Overview
Problem
Existing methods for producing back-contacting solar-cell modules result in unreliable electric connections and low yield due to the use of conductive adhesives in the lamination process.
Innovation Solution
A method involving the use of a first stacked member with electrically conducting protrusions and a second stacked member with electrically conducting sites, where gluing and insulating space rings are used to establish a stable electric connection by abutting the protrusions with the sites during lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive adhesive is used to realize electric connection and adhesion between back-contacting solar-cell sheet and metal circuit board, then adhesion is achieved, but electric connection reliability is poor and yield is low
Solution Approach 1:
The invention divides the connection function into two separate components: electrically conducting protrusions for electrical connection and gluing and insulating space rings for adhesion and insulation. This segmentation allows each component to perform its specific function optimally, with the protrusions providing reliable electrical contact and the rings providing mechanical bonding and electrical insulation, thereby resolving the contradiction between connection reliability and manufacturing complexity
Solution Approach 2:
The gluing and insulating space rings serve as an intermediary element between the electrically conducting protrusions and the metal circuit board. These rings provide both mechanical adhesion and electrical insulation, enabling the protrusions to make stable electrical contact while preventing short circuits, thus improving electric connection reliability without complicating the manufacturing process
2Reliability
If conductive adhesive is used for lamination, then adhesion is realized, but electric connection yield is low
Solution Approach 1:
By separating the adhesion function (performed by gluing and insulating space rings) from the electrical connection function (performed by electrically conducting protrusions), the invention eliminates the need for conductive adhesive, thereby improving electric connection yield while reducing adhesive material consumption
Solution Approach 2:
The invention extracts the electrical connection function from the adhesive material by introducing dedicated electrically conducting protrusions. This extraction allows the adhesive (in the form of space rings) to focus solely on mechanical bonding, improving both connection yield and reducing the quantity of conductive adhesive required
3Reliability
If conductive adhesive is used to achieve electric connection, then connection is established, but connection stability is poor
Solution Approach 1:
The connection structure is segmented into distinct functional elements: electrically conducting protrusions for stable electrical contact and gluing and insulating space rings for mechanical support and insulation. This segmentation enhances connection stability by providing dedicated structures for each function, while the modular nature of the segments keeps the overall structural complexity manageable
Solution Approach 2:
The electrically conducting protrusions and gluing and insulating space rings are self-structuring elements that automatically achieve their functions during the lamination process. The protrusions self-align to make electrical contact, and the space rings self-position to provide adhesion and insulation, improving connection stability without requiring complex external control mechanisms
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 enhances the reliability and yield of the electric connection in back-contacting solar-cell modules by eliminating the need for adhesive fusion, ensuring a stable connection without physical or chemical changes to the protrusions during lamination.
Implementation Method 1
the electrically conducting protrusions abut the second electrically conducting sites
Implementation Method 2
the gluing and insulating space rings glue the first sheet member and the second sheet member together
Implementation Method 3
gluing and insulating space rings are provided at peripheries of the first electrically conducting sites or peripheries of the second electrically conducting sites
Data Source
AI summary
A method for producing a back-contacting solar-cell module and a back-contacting solar-cell module. The method includes: providing a first stacked member, wherein the first stacked member includes a first sheet member; a surface of the first sheet member is provided with a plurality of first electrically conducting sites; the first stacked member further includes electrically conducting protrusions that are formed on the first electrically conducting sites of the first sheet member, gluing and insulating space rings at the peripheries of the first electrically conducting sites; providing a second stacked member, wherein the second stacked member includes a second sheet member; a surface of second sheet member is provided with a plurality of second electrically conducting sites; stacking and laminating first stacked member and second stacked member, the electrically conducting protrusions abut second electrically conducting sites, gluing and insulating space rings glue first sheet member and second sheet member together.