Back-Contact Cell String Soldering With Simultaneous Ribbon Clamping

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Solution Overview

Problem

Conventional soldering technologies for solar cells fail to achieve high-precision soldering of back contact cells due to ineffective ribbon production and positioning, leading to poor soldering precision.

Innovation Solution

A method involving a soldering device with a platform, clamping portions, and a heater that simultaneously clamps, transfers, and solder ribbons to back contact cells, ensuring precise alignment and connection by facing the back surfaces upward, and using cutting members to trim ribbons at specific gaps for improved precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional series soldering technology is used, then the soldering process can be completed, but the soldering precision is poor and cannot meet high-precision requirements

Engineering Contradiction:

Improvesoldering precisionVSAvoidribbon production and positioning effectiveness

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-positioning multiple ribbons on the electrodes of multiple back contact cells simultaneously before soldering. The clamping portions clamp the ribbons in advance to ensure precise positioning, and then all ribbons are soldered simultaneously using the heater, eliminating the need for sequential positioning and soldering operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges multiple ribbon positioning and soldering operations into a single simultaneous process. Multiple clamping portions work together to position multiple ribbons at once, and the heater simultaneously soldering all ribbons to their respective cells, transforming a sequential process into a parallel operation that improves both precision and efficiency.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If multiple ribbons are positioned and soldered sequentially, then each ribbon can be individually placed, but the production efficiency is low

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsoldering time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent implements continuity of useful action by enabling simultaneous positioning and soldering of multiple ribbons. The clamping portions and heater operate together in a continuous process where all ribbons are clamped, positioned, and soldered in one coordinated action, eliminating idle time between sequential operations and maximizing productive work time.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The clamping portions perform preliminary positioning of multiple ribbons simultaneously before the soldering action begins. This pre-positioning ensures that when the heater is activated, all ribbons are already in their correct positions, allowing the soldering process to proceed without interruption or repositioning, thereby reducing total processing time.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If fingers with opposite polarity are placed closer to busbars, then current collection area is increased, but short circuit risk increases

Engineering Contradiction:

Improvecell efficiencyVSAvoidshort circuit prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces mechanical positioning methods with a controlled soldering system that uses clamping portions and a heater to precisely position and secure ribbons. This systematic approach ensures accurate placement of fingers with opposite polarity closer to busbars while maintaining proper spacing through controlled soldering, preventing short circuits through precise thermal processing rather than relying solely on mechanical alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances soldering precision and production efficiency, reduces production costs, and allows for closer placement of fingers with opposite polarity to busbars without short circuits, improving cell and module efficiency by enabling current collection from more areas.

Implementation Method 1

heating the plurality of ribbons by using a heater to connect the plurality of ribbons to the plurality of back contact cells

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20230282761A1Method for soldering solar cell, cell string, photovoltaic module, and soldering device

Publication Date: 2023.09.07 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 to-be-connected ribbons; placing the plurality of to-be-connected 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 a heater to connect the plurality of ribbons to the plurality of back contact cells.