Conductive Component Layout for Flux-Controlled Solar Cell Bonding
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Solution Overview
Problem
The use of metal wires entirely soaked with flux in the busbarless adhesive bonding process leads to insufficient bonding force between the metal wires and the cell, resulting in poor and loose solder joints, which affects the performance of photovoltaic modules.
Innovation Solution
A conductive component with alternating welding and adhesive bonding regions, where flux parts are applied only in the welding regions, ensuring a reliable welding connection and adhesive bonding without interfering with the adhesive's catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal wires are entirely soaked with flux to ensure firm alloy connection, then welding reliability is improved, but bonding force between metal wires and adhesive decreases
Solution Approach 1:
The conductive component is divided into distinct welding regions and adhesive bonding regions along its length. Flux is applied only to the welding regions, while the adhesive bonding regions remain free of flux. This spatial segmentation allows the flux to enhance welding reliability without interfering with the adhesive bonding process, as the adhesive can properly bond to the metal wire surface in flux-free zones.
Solution Approach 2:
Different regions of the conductive component are given different surface properties: welding regions are treated with flux to improve metallurgical bonding, while adhesive bonding regions maintain a clean, flux-free surface to optimize adhesive attachment. This local differentiation of surface quality ensures each region performs its specific function effectively without compromising the other.
2Reliability
If flux is applied to metal wires for alloy connection, then welding firmness is improved, but catalytic activity of adhesive is inhibited
Solution Approach 1:
The conductive component is divided into distinct welding regions and adhesive bonding regions along its length. Flux is applied only to the welding regions, while the adhesive bonding regions remain free of flux. This spatial segmentation allows the flux to enhance welding reliability without interfering with the adhesive bonding process, as the adhesive can properly bond to the metal wire surface in flux-free zones.
Solution Approach 2:
The harmful flux substance is extracted or removed from the adhesive bonding regions of the conductive component. By applying flux selectively only to welding regions and excluding it from adhesive bonding zones, the harmful effect of flux on adhesive catalytic activity is eliminated while preserving the beneficial welding effects where flux is applied.
3Reliability
If flux is applied to metal wires to ensure alloy connection, then welding reliability is improved, but bonding force between adhesive and metal wire reduces
Solution Approach 1:
The conductive component is divided into distinct welding regions and adhesive bonding regions along its length. Flux is applied only to the welding regions, while the adhesive bonding regions remain free of flux. This spatial segmentation allows the flux to enhance welding reliability without interfering with the adhesive bonding process, as the adhesive can properly bond to the metal wire surface in flux-free zones.
Solution Approach 2:
Different regions of the conductive component are given different surface properties: welding regions are treated with flux to improve metallurgical bonding, while adhesive bonding regions maintain a clean, flux-free surface to optimize adhesive attachment. This local differentiation of surface quality ensures each region performs its specific function effectively without compromising the other.
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 design enhances the bonding force between the conductive component and the cell, ensuring reliable connections and preventing loose solder joints, thus maintaining the performance and efficiency of the photovoltaic module.
Implementation Method 1
Each of the flux parts is at least partially coated, along a perimetral direction of the conductive component, on the conductive component in a corresponding one of the welding regions
Implementation Method 2
The connection between these metal wires or conductive material wires and the cells is typically achieved through alloy connections, such as metal welding, or non-alloy connections, such as adhesive bonding
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present application relates to a conductive component, a solar cell string, and a photovoltaic module. An outer periphery of the conductive component (130) is defined with a plurality of welding regions (131) and a plurality of adhesive bonding region (132). The welding regions and the adhesive bonding regions are arranged alternately in a first direction. The outer periphery of the conductive component is provided with a plurality of flux parts (135) respectively corresponding to the plurality of welding regions. Each of the flux parts is at least partially coated, along a perimetral direction of the conductive component, on the conductive component in a corresponding one of the welding regions.