Flexible Circuit Interconnection for Solar Cells
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Solution Overview
Problem
Traditional solar cell interconnections using rigid metal ribbons limit the flexibility of thin-film flexible solar cells, making them unsuitable for integration into small electronic devices due to increased weight and reduced bend radius, and are costly to manufacture.
Innovation Solution
The use of flexible circuits with insulation materials and conductive wires, where the conductive wires are enclosed within the insulation and terminated with conductive adhesive, allowing for flexible interconnects that can be placed at arbitrary locations and eliminating the need for insulation when properly aligned, enabling the integration of flexible solar cells into various electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid metal ribbons are used for solar cell interconnections, then electrical conductivity is ensured, but flexibility and bend radius are reduced
Solution Approach 1:
The patent replaces rigid metal ribbons with thin-film flexible solar cells that have printed conductive patterns. The flexible substrate allows the solar cells to be bent and conform to various surfaces while maintaining electrical conductivity through the printed conductive traces, thus resolving the contradiction between rigidity for conductivity and flexibility for adaptability.
Solution Approach 2:
The patent substitutes traditional mechanical metal ribbon interconnections with printed conductive patterns on flexible substrates. This replacement eliminates the need for rigid mechanical connections while maintaining electrical conductivity, enabling the solar cells to achieve both flexibility and reliable electrical performance.
2Reliability
If traditional metal ribbons are used for interconnections, then electrical connection is reliable, but weight increases
Solution Approach 1:
The patent uses thin-film flexible substrates with printed conductive patterns instead of thick metal ribbons. This thin-film approach dramatically reduces the weight of the interconnection system while maintaining reliable electrical connections through the conductive traces printed on the flexible substrate.
Solution Approach 2:
The patent employs printed conductive patterns on flexible substrates that are lighter and more cost-effective than traditional metal ribbons. This approach reduces both weight and manufacturing cost while providing sufficient electrical connection reliability for the application.
3Reliability
If traditional metal ribbons are used for interconnections, then electrical conductivity is maintained, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive metal ribbon fabrication processes with printed conductive patterns on flexible substrates. This substitution enables more cost-effective manufacturing while maintaining electrical conductivity through the printed traces, thus resolving the contradiction between reliable electrical connection and manufacturing cost.
Solution Approach 2:
The patent changes the manufacturing approach from metal ribbon fabrication to printed conductive patterns. This parameter change in the manufacturing process reduces costs while maintaining electrical conductivity, making the solar cells more economically viable for various applications.
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 solution maintains the intrinsic flexibility of thin-film solar cells, simplifies integration, reduces manufacturing costs, and allows for wider application in portable electronics, sensors, and other devices by eliminating the need for traditional ribbon routing and insulation, while maintaining electrical conductivity.
Implementation Method 1
The insulation material includes openings with electrically conductive adhesive that provide electrical conductivity between the contacts of the one or more solar panels and the conductive wires
Data Source
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AI summary
A flexible circuit that allows a standardized connection interface to connect flexible solar cell(s) for easy integration into electronics devices. This interconnection scheme does not limit the intrinsic solar cell flexibility and may conform to standard design practices in electronic device manufacturing. In an aspect, a solar module is described that includes one or more solar panels and a flexible trace or interconnect having conductive wires inside an insulation material. In another aspect, an electronic device is described that includes a circuit board, one or more solar panels and a flexible trace or interconnect having conductive wires inside an insulation material. The electronic device may be an internet-of-things (loT) device or an unmanned aerial vehicle (UAV), for example. In yet another aspect, a lighting module is described that includes one or more lighting panels and a flexible trace or interconnect having conductive wires inside an insulation material.