Back-Contact Solar Cell Strip Welding for Continuous Interconnection
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Solution Overview
Problem
The traditional welding process of solar cell chips is tedious and prone to defective products due to the need to weld positive and negative electrodes on different surfaces simultaneously.
Innovation Solution
A welding method for back-contact solar cell chips that allows for rapid and continuous welding of the welding strip without cutting the interconnected bar, involving steps such as forming small cell strings, punching into separate assemblies, welding with a bus bar, and post-cutting to form connected cell assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the traditional welding process welds positive and negative electrodes on different surfaces simultaneously, then both surfaces can be welded, but the process becomes tedious and the probability of defective products increases
Solution Approach 1:
The patent inverts the traditional welding approach by placing both positive and negative electrodes on the same surface of the solar cell chip. Instead of welding different surfaces separately, the interconnected bar now connects both electrodes on a single surface, simplifying the welding process to one operation rather than two separate surface welding operations.
Solution Approach 2:
The patent merges the welding operations for positive and negative electrodes into a single welding process. By positioning both electrodes on the same surface, the interconnected bar can weld both electrodes simultaneously in one operation, combining what were previously separate welding steps into a unified process.
2Ease of manufacture
If the interconnected bar is cut after positive electrode welding strip arrangement, then the welding strip can be prepared, but the welding process becomes more complex and time-consuming
Solution Approach 1:
The patent eliminates the preliminary cutting action of the interconnected bar. Instead of cutting the bar after arranging the positive electrode welding strip, the design allows the interconnected bar to extend continuously and weld both positive and negative electrodes without intermediate cutting or rearrangement steps.
3Reliability
If both surfaces are welded simultaneously with the interconnected bar, then complete welding is achieved, but the working efficiency decreases due to the tedious process
Solution Approach 1:
The patent inverts the traditional approach of welding different surfaces by placing both electrodes on the same surface. This allows the interconnected bar to weld both positive and negative electrodes in a single continuous operation on one surface, achieving complete welding without the inefficiency of multi-surface sequential welding.
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 reduces the difficulty of the welding process, improves working efficiency, and decreases the likelihood of defective products by ensuring that both electrodes are welded on the same surface, allowing for simultaneous welding of multiple main grids.
Implementation Method 1
moving an infrared welding head down to touch the interconnected bar to start welding, so that the interconnected bar is uniformly and firmly fused with a welding joint of the small chip assembly
Data Source
AI summary
A welding method for a welding strip of a back-contact solar cell chip includes the following steps: firstly, welding small chip assemblies of a back-contact solar cell to be interconnected to form a small cell string through an interconnected bar; then, punching the small cell string into small cell assemblies separated from each other through a cutting or punching process; subsequently, flexibly welding the small cell assemblies by a bus bar to reach a required length of a finished assembly product; and finally, breaking the bus bar through a post cutting or punching process to form cell assemblies with positive and negative electrodes connected in series or in parallel. The method makes the welding surfaces of the solar cell chips be on the same surface through using the back-contact solar cell chips, so that the interconnected bar of the solar cell chips can be welded rapidly and continuously.