Single-Side Colored Conductive Ribbon for Low-Shading Solar Modules
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Solution Overview
Problem
Conventional solar module conductive ribbons are inefficient due to shading and contamination, and lack aesthetic appeal as they are typically solid and uncoated, which can decrease energy output and clash with the module's appearance.
Innovation Solution
The development of colored electrically conductive ribbons with a color coating on one side, applied using methods like screen-coating, roll-coating, or spray-coating, and cured using heat or UV, which are designed to be attached to solar cells or modules without coating the bottom side to prevent shading and contamination, while also improving aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional uncoated conductive ribbons are used, then electrical conductivity is maintained, but aesthetic appearance deteriorates and contamination resistance worsens
Solution Approach 1:
The patent applies a color coating only to one side of the conductive ribbon (the side facing outward on the solar module), while leaving the other side uncoated. This local differentiation allows the coated side to provide aesthetic appearance and contamination resistance, while the uncoated side maintains optimal electrical conductivity and adhesion properties for connecting to solar cells.
Solution Approach 2:
The patent creates a composite structure by applying a color coating layer over the conductive ribbon substrate. This composite construction combines the electrical conductivity of the metal ribbon with the aesthetic and protective properties of the color coating, achieving multiple functions simultaneously.
2Ease of manufacture
If conductive ribbons are coated on both sides, then aesthetic appearance improves, but energy output decreases due to shading
Solution Approach 1:
The patent applies the color coating selectively only to one side of the conductive ribbon, specifically the side that will be visible on the solar module exterior. This unilateral coating approach provides aesthetic benefits while preventing the coating from interfering with light transmission to the solar cells, thus avoiding energy output reduction.
3Object-affected harmful factors
If conductive ribbons are coated, then contamination resistance improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies coating only to one side of the conductive ribbon using selective masking techniques during the coating process. This localized approach provides contamination resistance where needed (on the exposed side) while avoiding unnecessary coating on the attachment side, thereby limiting the increase in manufacturing complexity to only the coating application step.
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 colored conductive ribbons enhance energy efficiency by minimizing shading and contamination, while also providing an aesthetically pleasing appearance that matches the solar module's color, thereby improving both performance and visual integration.
Implementation Method 1
the step of curing the color coating in d) may be performed by heat-curing or UV (ultraviolet light) curing
Data Source
AI summary
The present disclosure describes methods of forming a colored conductive ribbon for a solar module which includes combining a conductive ribbon with a channeled ribbon holder, applying a color coating to at least the conductive ribbon within the channel, curing the color coating on the conductive ribbon, and separating the conductive ribbon from the channeled holder.