Flexible Solar Cell Circuit for Weld-Free Modular Assembly

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Solution Overview

Problem

The existing assembly methods for solar cell systems are impractical and costly, requiring multiple components and steps, including welding, which reduces flexibility and increases handling costs, especially for end users.

Innovation Solution

A solar cell assembly with a flexible circuit that includes a flexible insulator with embedded metal traces and exposed contacts, allowing for easy alignment and connection of adjacent solar cells without extensive welding, enabling quick, adaptive, and modular system configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional welding methods are used to interconnect solar cells, then reliable electrical connections are achieved, but assembly complexity and handling costs increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the electrical connection function and mechanical support function into a single integrated flexible circuit board. The FCB serves both as the interconnection medium for electrical continuity and as the structural framework holding solar cells, eliminating the need for separate welding operations and multiple components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible circuit board acts as an intermediary component between solar cells, providing pre-fabricated connection points and conductive traces that eliminate direct welding between cells. The FCB mediates the electrical connection through its embedded circuitry, reducing assembly steps and handling requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If multiple components and assembly steps are used to interconnect solar cells, then robust electrical connections are achieved, but assembly time and productivity are reduced

Engineering Contradiction:

Improveelectrical connection robustnessVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The flexible circuit board is pre-assembled with electrical connections, connection terminals, and mounting structures before being installed with the solar cells. This preliminary preparation of the FCB allows for rapid deployment during final assembly, significantly reducing on-site assembly time while maintaining connection robustness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent divides the solar cell system into modular units where each solar cell is independently mounted on a standardized flexible circuit board. This segmentation allows for parallel assembly processes and simplifies the interconnection of multiple cells, improving overall assembly productivity without compromising connection quality.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If solar cells are pre-assembled by manufacturers, then assembly quality is improved, but handling costs and user flexibility increase

Engineering Contradiction:

Improveassembly qualityVSAvoidhandling cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The flexible circuit board is designed as a universal platform that can accommodate different solar cell types and configurations while maintaining standardized connection interfaces. This multi-functionality allows single pre-assembled FCB units to serve various applications, reducing the need for multiple specialized components and lowering handling costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If extensive welding is performed to connect solar cells, then reliable electrical interconnection is achieved, but shadowing and resistive losses increase

Engineering Contradiction:

Improveelectrical interconnection reliabilityVSAvoidresistive losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical welding process with electrical connections through conductive traces on the flexible circuit board. This substitution eliminates the need for physical welding joints that create resistance and shadowing, using instead low-resistance printed or etched conductive paths that minimize energy losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3958332B1Flexible circuit for solar cell assemblies

Publication Date: 2023.10.04 THE BOEING CO

Figure 1A
Figure 1B
Figure 2A~2B

AI summary

A solar cell assembly having a flexible circuit is described. The solar cell assembly includes a solar cell having a solar-facing surface and a non-solar-facing surface, the solar cell comprising a cell corner. The solar cell assembly further includes a flexible circuit coupled to the non-solar-facing surface of the solar. The flexible circuit is substantially coextensive with the solar cell. The flexible circuit includes a flexible insulator including a plurality of edges aligned with the solar cell, a flexible corner extending past the cell corner, and a flexible tab extending from an edge of the plurality of edges. The flexible circuit includes a circuit substantially embedded in the flexible insulator. The circuit comprises a first electric contact exposed at a solar-facing side of the flexible corner, and a second electric contact exposed at a solar-facing side of the flexible tab. (Fig. 3)