Back-Contact Cell String Soldering With Clamped Ribbon Positioning

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Solution Overview

Problem

Conventional series soldering technologies fail to produce and position ribbons effectively for solar cells, resulting in poor soldering precision, especially for high-precision back contact cells.

Innovation Solution

A method involving a soldering device with a platform, clamping portions, and a heater, where back contact cells are placed with their back surfaces facing upwards, and ribbons are simultaneously clamped, transferred, and soldered to connect them to the cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional series soldering technology is used, then the process is simple, but soldering precision is poor

Engineering Contradiction:

Improvesoldering precisionVSAvoidsoldering device complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The soldering device is divided into multiple independent modules including a placement module with clamping portions for positioning ribbons, a heating module with heaters for soldering, and a transport module. Each module performs a specific function, allowing precise control of ribbon placement and soldering processes while maintaining modular simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Clamping portions are introduced as intermediary components between the ribbon and the solar cells. These clamping portions precisely position the ribbons on the electrodes before soldering, ensuring high soldering precision without requiring complex direct positioning mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional series soldering is used, then equipment is simple, but production efficiency is low

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsoldering device complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple functions are merged into an integrated soldering device: the placement module positions multiple ribbons simultaneously, the heating module solders multiple connections at once, and the transport module moves components in coordination. This combined approach achieves high production efficiency while keeping the device structure manageable

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clamping portions perform preliminary positioning of the ribbons on the electrodes before the soldering process begins. This preliminary action ensures precise alignment and enables subsequent rapid soldering of multiple connections simultaneously, improving overall production efficiency

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If ribbons are positioned by conventional methods, then positioning is simple, but soldering precision for back contact cells is insufficient

Engineering Contradiction:

Improveribbon positioning precisionVSAvoidribbon placement ease

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Clamping portions serve as intermediary positioning elements that grip the ribbons and precisely locate them on the electrodes of back contact cells. This intermediary mechanism achieves high positioning precision while maintaining ease of operation through automated clamping and release actions

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The clamping portions are designed with localized gripping features that specifically engage with the ribbon structure at critical points. This localized quality ensures precise positioning at the ribbon-electrode interface without requiring complex overall positioning systems

Inventive Principle:

Principle #3Local quality

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 improves soldering precision and production efficiency, reduces costs, and allows for closer placement of fingers with opposite polarities to busbars without short circuits, enhancing cell and component efficiency.

Implementation Method 1

heating the plurality of ribbons by using at least one heater to connect the plurality of ribbons to the plurality of back contact cells

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

A solar cell converts sunlight to electric energy by means of a photovoltaic effect of a semiconductor p-n junction

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS20250194265A1Method for soldering solar cell, cell string, photovoltaic component, and soldering device

Publication Date: 2025.06.12 SOLARLAB AIKO EUROPE GMBH

AI summary

A method for soldering a solar cell, includes: placing a plurality of back contact cells on a soldering platform, where back surfaces of the back contact cells face away from the soldering platform, and electrodes corresponding to two adjacent back contact cells have opposite polarities in a connection direction of a plurality of ribbons which are to be connected; placing the plurality of ribbons on the electrodes of the plurality of back contact cells by using a first clamping portion, a second clamping portion, and a plurality of third clamping portions, where the first clamping portion, the second clamping portion, and the plurality of third clamping portions respectively correspond to head ends, tail ends, and middle portions of the plurality of ribbons; and heating the plurality of ribbons by using at least one heater to connect the plurality of ribbons to the plurality of back contact cells.