Flexible Silicon Solar Module Welding With Pre-Attached Cell Protection
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Solution Overview
Problem
Traditional welding methods for silicon-based solar modules are inefficient, as they lack protection for fragile cell pieces, leading to damage and reduced production quality, and are not highly automated, affecting production capacity.
Innovation Solution
A method involving laser cutting of cell pieces into strings with attached hard protective layers, automated arrangement, and serial welding with adhesive films to form flexible and rollable modules, reducing breakage and improving quality through protective layer coverage and automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard protective layer is attached before welding, then the broken probability of small cell pieces is reduced, but the process complexity increases
Solution Approach 1:
The hard protective layer is attached to the cell piece before welding operations in advance, so that during subsequent welding and handling, the cell piece is already protected and cannot be damaged. This preliminary protective action eliminates the need for complex protective measures during welding and resolves the contradiction between reliability improvement and process complexity increase.
2Adaptability or versatility
If the small cell is completely divided into pieces and then arranged, then the flexibility of arrangement is improved, but the production capacity is reduced due to tedious process
Solution Approach 1:
The cell piece is divided into multiple small cell pieces that can be independently arranged and configured. Each small cell piece maintains its functionality while allowing flexible arrangement patterns. This segmentation enables adaptability in module design without significantly impacting production capacity when combined with automated welding systems.
3Device complexity
If the protective layer is glue-dispensed and fitted after interconnecting strip welding, then the welding process is simplified, but the small cell piece is welded without protection leading to damage
Solution Approach 1:
The hard protective layer is attached to the cell piece before welding operations in advance, so that during subsequent welding and handling, the cell piece is already protected and cannot be damaged. This preliminary protective action eliminates the need for complex protective measures during welding and resolves the contradiction between reliability improvement and process complexity increase.
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 method significantly reduces breakage and production loss, enhances product quality, and increases automation, simplifying the process by using a hard protective layer and strategic electrode welding to safeguard fragile parts during the assembly of flexible and rollable silicon-based solar modules.
Implementation Method 1
cutting a cell piece into a small piece cell string including N small piece cells without splitting by laser cutting
Implementation Method 2
fixing the 1P standard parts by bonding the adhesive films to each other
Data Source
AI summary
A welding method for a new flexible and rollable silicon-based solar module includes the following steps: cutting a cell piece into a small piece cell string including N small piece cells without splitting; cutting a hard protective layer into N small pieces according to a size of a small piece cell; allowing the cut hard protective layer to be covered on and bonded to a glue-dispensed small piece cell string to form a small string cell piece; arranging the small string cell pieces into a small standard piece according to a required size distribution, and covering the small standard piece with an adhesive film; welding positive electrodes and negative electrodes of the small standard pieces in series simultaneously to form a 1P standard part; and arranging the 1P standard parts, and fixing the 1P standard parts by bonding the adhesive films to each other to form a 5P standard part.