Converging Busbar Layout for Lower-Material Solar Cells
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Solution Overview
Problem
The photovoltaic industry faces challenges in cost control due to fluctuating prices of silver paste and solder strips, with existing busbar electrode designs struggling to reduce consumption effectively, leading to bottlenecks in material usage and manufacturing efficiency.
Innovation Solution
The introduction of a converging busbar design in solar cells, which separates the cell surface into regions with differently oriented sub-busbars and main busbars, optimizing the layout to minimize silver paste and solder strip consumption by reducing the number of soldering spots and improving current collection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional busbar electrode design is used, then current collection is achieved, but silver paste and solder strip consumption is high and costs are difficult to control
Solution Approach 1:
The busbar electrode is divided into multiple segments including a first busbar, a second busbar, and multiple sub-busbars. This segmentation allows for optimized current collection paths and reduced material usage in each segment, thereby reducing overall silver paste consumption while maintaining electrical performance
Solution Approach 2:
Different regions of the busbar electrode are designed with different properties: the first and second busbars have different widths and positions, and sub-busbars are strategically placed to optimize current collection in high-density regions while reducing material usage in low-density regions
2Loss of substance
If conventional busbar electrode design is used, then current collection is achieved, but solder strip consumption is high and manufacturing costs increase
Solution Approach 1:
The first busbar and second busbar are positioned to enable merging of current collection paths, allowing fewer solder strips to connect multiple sub-busbars to the main busbars, thereby reducing solder strip consumption while maintaining electrical connectivity
Solution Approach 2:
The busbar electrode design incorporates three-dimensional positioning with busbars at different heights and depths, allowing for optimized solder strip routing and reduced solder strip length while maintaining effective current collection from all sub-busbars
3Ease of manufacture
If conventional busbar layout is used, then manufacturing is simplified, but the number of soldering spots is high increasing defect risk
Solution Approach 1:
The design extracts and consolidates multiple soldering connections into fewer critical soldering spots by using main busbars that collect current from multiple sub-busbars. This reduces the total number of soldering operations while maintaining current collection effectiveness, thereby reducing defect risk
Solution Approach 2:
The busbar electrode structure is pre-configured with optimized busbar positions and sub-busbar arrangements that minimize the number of required soldering spots before the soldering process begins, allowing for more controlled and reliable soldering operations
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 reduces the consumption of silver paste and solder strips by up to 30%, decreases the risk of soldering micro-cracks and cold solder joints, and enhances productivity by increasing the yield of module manufacturing, thereby lowering costs and improving the efficiency of current collection.
Implementation Method 1
The present disclosure relates to the field of solar cell technologies
Data Source
AI summary
A solar cell and a solar cell module can include a converging busbar. The converging busbar separates a first surface of the solar cell into a first region and a second region. The first region includes a plurality of first sub-busbars spaced along a first direction and a plurality of main busbars spaced along a second direction, and the main busbar is electrically connected to the first sub-busbar. The second region includes a plurality of second sub-busbars spaced along a third direction. The converging busbar is located between the first region and the second region, and is electrically connected to the plurality of main busbars and the plurality of second sub-busbars.