Electrode Tape Manufacturing Machine for Solar Cells
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Solution Overview
Problem
The traditional soldering process for forming metal electrodes on solar cells can cause micro cracks due to thermal expansion/shrinkage coefficient differences between metal electrodes and crystalline silicon substrates, affecting the efficiency and reliability of solar cells.
Innovation Solution
A machine for manufacturing electrode tape that includes a conveyor with a molding belt, a conductive structure coil, an adhesive material supply unit, and a curing unit, which forms a double-sided adhesive electrode tape with exposed contact points, allowing for secure adhesion to solar cells without the need for high-temperature soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional soldering process is used to form metal electrodes on solar cells, then strong electrical connection is achieved, but micro cracks are generated on the solar cell surface due to thermal expansion/shrinkage coefficient difference
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical adhesive bonding process. The electrode tape uses adhesive material to bond the conductive structure (metal electrodes) to the solar cell surface, eliminating the need for high-temperature soldering that causes thermal stress and micro cracks. This substitution of bonding mechanism directly resolves the contradiction between achieving strong electrical connection and preventing thermal damage.
Solution Approach 2:
The patent changes the bonding temperature parameter from high temperature (soldering) to room temperature or low temperature (adhesive bonding). The adhesive material is applied and cured at temperatures that do not cause thermal expansion/shrinkage coefficient differences, thereby preventing micro crack formation while still achieving adequate bonding strength for electrical connection.
2Reliability
If high-temperature soldering is performed to secure metal electrodes, then reliable electrical connection is achieved, but thermal stress causes micro cracks affecting solar cell reliability
Solution Approach 1:
The patent substitutes the thermal field (soldering) with a chemical field (adhesive bonding). The adhesive material creates reliable electrical connection through chemical bonding and mechanical adhesion at low temperatures, eliminating thermal stress and its harmful effects on solar cell reliability.
Solution Approach 2:
The adhesive material acts as an intermediary substance between the conductive structure (metal electrodes) and the solar cell substrate. This intermediary enables reliable bonding and electrical connection without direct thermal contact between the metal and the solar cell, thereby preventing thermal stress and micro crack formation.
3Strength
If adhesive material is applied to cover the entire conductive structure, then secure adhesion is achieved, but contact points for electrical connection are blocked
Solution Approach 1:
The patent applies adhesive material selectively to specific regions (sidewalls of the conductive structure) rather than uniformly across the entire surface. This local application ensures adequate adhesion strength where needed while leaving the contact points (top and bottom surfaces) exposed for electrical connection, resolving the contradiction between adhesion strength and electrical connectivity.
Solution Approach 2:
The patent segments the conductive structure into different functional regions: sidewalls for adhesion (covered with adhesive material) and contact points for electrical connection (kept exposed). This segmentation allows the adhesive to provide secure bonding without interfering with the electrical connection function, achieving both adhesion strength and electrical reliability simultaneously.
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 electrode tape solution reduces the risk of micro cracks by providing a secure, adhesive-based connection between metal electrodes and solar cells, enhancing the reliability and efficiency of solar cell assemblies while minimizing thermal stress.
Implementation Method 1
a curing unit (740) rather than a heating unit (640), and the UV irradiation unit (740) is used to cure the adhesive material (631) fed on the surface of the molding belt (611)
Implementation Method 2
The heating unit (640), for example, an oven, is positioned at a middle section of the molding belt (611) and is used to remove solvent contained in the adhesive material (631) and cure the adhesive material (631)
Implementation Method 3
The first means is used for adhering an adhesive material to a sidewall of a conductive structure
Data Source
AI summary
A machine for manufacturing an electrode tape is disclosed. The machine includes a conveyor, a conductive structure coil, an adhesive material supply unit and a curing unit. The conveyor includes a molding belt with at least one groove and a roller used to drive the molding belt. The conductive structure coil is adapted to provide a conductive structure to the at least one groove of the molding belt. The adhesive material supply unit is adapted to provide an adhesive material to a surface of the molding belt. The curing unit is adapted to cure the adhesive material provided on the surface of the molding belt into a film.