Blackened Electroformed Metallic Articles for Solar Modules
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Solution Overview
Problem
Solar cell modules have aesthetically unpleasing electrical contacts and interconnections that are visible, affecting their appearance in various applications, and existing solutions like dot patterns reduce efficiency by blocking light.
Innovation Solution
The use of electroformed metallic articles with patterned metal layers, coated with a blackening material to create a 'blackened' surface that matches the solar cell, replacing conventional bus bar metallization and ribbon stringing, while maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional shiny metal electrical contacts and interconnections are used, then electrical conductivity is maintained, but aesthetic appearance deteriorates due to visibility and light reflection
Solution Approach 1:
The patent applies a blackening process to the metallic article, transforming its surface color from shiny silver to matte black. This color change makes the electrical contacts and interconnections visually blend with the solar cell surface, eliminating the aesthetic issue of visible shiny metal while maintaining the underlying electrical functionality
Solution Approach 2:
The patent creates a composite structure by combining the metallic article (copper or copper alloy) with a blackening coating layer. This composite material approach allows the base metal to provide electrical conductivity while the blackening layer provides aesthetic appearance and light absorption, resolving the contradiction between functionality and appearance
2Shape
If dot pattern is applied on cover glass to improve appearance, then aesthetic appearance is improved, but light transmission is blocked reducing solar cell efficiency
Solution Approach 1:
The patent removes the dot pattern layer from the cover glass and instead applies the blackening treatment directly to the metallic article itself. This extraction of the aesthetic modification from the optical path (cover glass) to the electrical component (metallic article) eliminates light blocking while maintaining appearance improvement
Solution Approach 2:
The blackening coating on the metallic article serves as an intermediary that absorbs light without interfering with the electrical functionality. Unlike dot patterns on cover glass that block light before it reaches the cell, the blackened metal articles absorb light after it has passed through the cover glass and been utilized by the solar cell, thus maintaining efficiency while improving appearance
3Shape
If blackening material is applied to metallic article, then aesthetic appearance is improved by matching solar cell color, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the blackening process with the existing electroforming manufacturing process by applying the blackening treatment while the metallic article is still on the mandrel. This integration of the aesthetic treatment into the existing manufacturing flow eliminates the need for separate handling and assembly steps, reducing overall manufacturing complexity despite adding a process step
Solution Approach 2:
The blackening process is performed preliminarily while the metallic article is still attached to the mandrel in the electroforming process, before the article is removed and assembled into the solar module. This preliminary action allows the blackening to be done in a controlled manufacturing environment and simplifies subsequent assembly operations
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
The solution improves the aesthetic appearance of solar modules without reducing efficiency, providing a uniform and stealthy appearance suitable for different applications, including military use, while maintaining performance.
Implementation Method 1
a blackening solution is applied to a metallic article to form a blackened layer
Implementation Method 2
a metallic article is electroformed in an electroforming mandrel. The metallic article includes a plurality of electroformed elements formed from copper or alloys of copper in a preformed pattern on an outer surface layer of the mandrel
Data Source
Figure 1~2C
Figure 3A~3B
Figure 4
AI summary
A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. A solder is plated on the second side of the plurality of electroformed elements while on the mandrel. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements. The solder on the second side of the plurality of electroformed elements is not blackened.