Busbar-Free Shingled Solar Cell Layout for Lower Silver Paste Use
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Solution Overview
Problem
Conventional shingled solar cells with busbars result in high silver paste consumption and increased production costs due to the large width and space occupation of busbars, lacking a significant cost advantage.
Innovation Solution
Designing a shingled cell with a front-side connection line that is narrower than the fine grid lines, eliminating busbars and ensuring effective current conduction by connecting the front-side fine grid lines of one cell unit to the back-side fine grid lines of the next unit, reducing electrode production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used in shingled solar cells, then current conduction is achieved, but silver paste consumption increases and production costs rise
Solution Approach 1:
The patent extracts and eliminates the busbar component from the solar cell structure, replacing it with fine grid lines that extend to the edges of the cell. This removal of the busbar directly reduces silver paste consumption while maintaining current conduction functionality through the modified fine grid line configuration
Solution Approach 2:
The patent changes the parameters of the grid line system by extending fine grid lines to the cell edges and configuring them to function as connection lines, replacing the traditional busbar-based connection method. This parameter change enables current conduction without requiring additional silver paste for busbars
2Reliability
If busbars are used in shingled solar cells, then current conduction is achieved, but production costs increase
Solution Approach 1:
By extracting and removing the busbar component, the patent eliminates the associated manufacturing costs for busbar production, handling, and assembly, thereby reducing overall production costs while maintaining current conduction through the modified fine grid line structure
Solution Approach 2:
The patent merges the functions of fine grid lines and connection lines into a single integrated structure, where the fine grid lines extend to the cell edges and serve as both current collection and inter-cell connection elements, simplifying the manufacturing process and reducing costs
3Reliability
If connection lines are designed to contact back-side fine grid lines, then effective current conduction is achieved, but precise positioning is required
Solution Approach 1:
The patent employs preliminary action through self-alignment mechanisms during the lamination process, where the overlap configuration and edge positioning are predetermined to automatically align the front-side connection lines with the back-side fine grid lines, reducing the need for high-precision manual positioning
Solution Approach 2:
The design enables self-service through the inherent geometric configuration of overlapping cells, where the connection lines and fine grid lines automatically contact each other based on the overlap distance and cell arrangement, allowing the structure to self-align during assembly without requiring complex positioning systems
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 design significantly reduces electrode production costs and manufacturing costs while maintaining efficient current conduction, enhancing the competitiveness of shingled assemblies.
Implementation Method 1
the front-side connection line is such configured that when two cell units are overlapped along the extension direction of the front-side fine grid lines, the front-side connection line of the lower cell unit contacts each of the back-side fine grid lines of the upper cell unit
Data Source
AI summary
Disclosed are a shingled cell, a cell unit, and a shingled photovoltaic assembly. The cell unit includes a cell. The front side of the cell includes a plurality of parallel front-side fine grid lines. The back side of the cell includes a plurality of parallel back-side fine grid lines and a front-side connection line. The front-side connection line is a continuous or non-continuous line segment. The front-side connection line is arranged on at least one side of the cell. The front-side connection line is connected to the ends of all the front-side fine grid lines on the same side. The front-side connection line is such configured that when two cell units are overlapped along the extension direction of the front-side fine grid lines, the front-side connection line of the lower cell unit contacts each of the back-side fine grid lines of the upper cell unit.