Backsheet Conductive Elements for Automated PV Panel Assembly
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Solution Overview
Problem
Conventional photovoltaic panel assembly processes face challenges such as complex circuit layouts leading to electrical connection issues, high labor costs, and quality control difficulties, particularly in large production volumes, with existing solutions not providing efficient, automated, and cost-effective methods for connecting the back junction box to photovoltaic panels without manual operations.
Innovation Solution
A backsheet with integrated non-through, double-contacting face conductive elements that allow for guided, direct electrical connection to the back junction box, eliminating manual handling and enabling automated assembly, suitable for both standard and back-contact type solar cells, using recessed seats and through-holes for precise and stable conductive bump contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used for electrical connection of the back junction box, then flexibility and adaptability are maintained, but labor costs increase and productivity decreases
Solution Approach 1:
Conductive elements are pre-integrated into the backsheet during manufacturing, with through-holes and recessed seats prepared in advance. This preliminary preparation enables automated insertion and connection of the back junction box without manual electrical connection operations, thereby increasing productivity while maintaining automation capability
Solution Approach 2:
The conductive elements integrated in the backsheet serve as intermediary components between the photovoltaic cells and the back junction box. These intermediaries (conductive elements with double contacting faces) facilitate automated electrical connection by providing pre-positioned contact points, eliminating the need for manual ribbon wiring while maintaining electrical connectivity
2Reliability
If complex circuit layouts are used to connect photovoltaic cells, then electrical connection flexibility is maintained, but connection reliability decreases and quality control becomes difficult
Solution Approach 1:
The electrical connection system is segmented into distinct functional components: conductive elements integrated in the backsheet, through-holes for alignment, recessed seats for positioning, and the back junction box. This segmentation simplifies the overall circuit layout by breaking down the complex connection process into standardized, manageable segments that are easier to control and verify for quality
Solution Approach 2:
The conductive elements with double contacting faces are designed to self-align and self-position within the recessed seats during automated assembly. The through-holes and recessed seats guide the conductive elements into correct positions automatically, enabling the system to self-service the alignment and positioning functions that would otherwise require complex manual adjustment, thereby improving reliability while reducing layout complexity
3Ease of manufacture
If through-type conductive elements are used for back junction box connection, then electrical connection is simplified, but structural stability and manufacturing precision decrease
Solution Approach 1:
The conductive elements are nested within recessed seats in the backsheet, with the recessed seats providing a precise cavity that accommodates the conductive elements. This nesting structure ensures that the conductive elements are precisely positioned and held firmly during automated assembly, maintaining manufacturing precision while allowing easy electrical connection through the through-holes
Solution Approach 2:
The backsheet is designed with localized features (through-holes and recessed seats) at specific positions corresponding to the electrical connection points. These local quality enhancements provide precise positioning and structural support exactly where needed for the conductive elements, without requiring high precision throughout the entire backsheet, thereby balancing ease of manufacture with manufacturing precision
Data Source
AI summary
Backsheet for photovoltaic panels with conductive interface elements intended to simplify the electrical connection of the terminal points of the circuit to the back junction box. The conductive elements are of the non-through type through the backsheet, with double contacting face, and are integrated on the front side towards the cells within recessed seats and in correspondence of through-holes in such a way as to enable an electrical connection by contact from the back side through the holes, in a guided way, by means of respective conductive elements protruding and fastened to the junction box. In particular, such a simplified contacting solution can be realized with extreme precision, without manual operations and at extremely low costs, with an automated assembly method.