Flux-Patterned Conductive Component for Solar Cell Bonding
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Solution Overview
Problem
The use of metal wires entirely soaked with flux in busbarless adhesive bonding processes in photovoltaic modules leads to reduced bonding force due to inhibition of adhesive activity by acidic substances in the flux, resulting in poor and loose solder joints, affecting module performance.
Innovation Solution
A conductive component with alternating welding and adhesive bonding regions, where flux is applied only in welding regions, ensuring reliable welding connections and avoiding contact with adhesive, thus maintaining bonding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal wires are entirely soaked with flux to ensure firm alloy connection, then welding reliability is improved, but adhesive bonding force is reduced due to inhibition of catalytic substance activity
Solution Approach 1:
The conductive component is divided into distinct welding regions and adhesive bonding regions along its length. Flux is selectively applied only to the welding regions, while the adhesive bonding regions remain free of flux. This spatial segmentation allows the flux to enhance welding reliability without interfering with adhesive bonding, as the harmful acidic substances are confined to areas where they provide benefit (welding) rather than where they cause harm (adhesive bonding).
Solution Approach 2:
Different regions of the conductive component are given different chemical properties through selective flux application. The welding regions possess flux-coated surfaces that promote reliable alloy connections, while the adhesive bonding regions maintain clean surfaces that allow maximum bonding force. This local differentiation of surface quality enables each region to optimize its specific function without compromising the other.
2Reliability
If flux is sprayed onto cells to provide fluxing substances, then alloy connection is improved, but uneven spraying causes flux residue and adverse effects
Solution Approach 1:
Instead of applying flux to the cells and hoping for even distribution, the flux is pre-applied to the conductive component in a controlled manner before the bonding process. This preliminary, targeted application ensures that flux is present exactly where needed (at the welding regions) in appropriate amounts, eliminating the randomness and unevenness associated with spraying flux onto cells.
Solution Approach 2:
The flux application process is extracted from the cell processing step and transferred to the conductive component preparation step. By taking out the flux application from the general cell processing flow and applying it selectively to specific regions of the conductive component, the method eliminates the problem of uneven spraying and flux residue on the cells.
3Reliability
If entire metal wire surface is provided with flux, then welding connection is enhanced, but bonding force between adhesive and metal wire is reduced due to alloy coating formation
Solution Approach 1:
The conductive component is divided into distinct welding regions and adhesive bonding regions along its length. Flux is selectively applied only to the welding regions, while the adhesive bonding regions remain free of flux. This spatial segmentation allows the flux to enhance welding reliability without interfering with adhesive bonding, as the harmful acidic substances are confined to areas where they provide benefit (welding) rather than where they cause harm (adhesive bonding).
Solution Approach 2:
Different regions of the conductive component are given different chemical properties through selective flux application. The welding regions possess flux-coated surfaces that promote reliable alloy connections, while the adhesive bonding regions maintain clean surfaces that allow maximum bonding force. This local differentiation of surface quality enables each region to optimize its specific function without compromising the other.
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
Ensures reliable connections between conductive components and solar cells, preventing loose solder joints and enhancing module performance by maintaining adhesive bonding force.
Implementation Method 1
Each of the flux parts is at least partially coated, along a perimetral direction of the conductive component, on the conductive component in a corresponding one of the welding regions
Implementation Method 2
The welding regions and the adhesive bonding regions are alternately arranged in a first direction
Data Source
AI summary
The present application relates to a conductive component, a solar cell string, and a photovoltaic module. An outer periphery of the conductive component is defined with a plurality of welding regions and a plurality of adhesive bonding region. The welding regions and the adhesive bonding regions are arranged alternately in a first direction. The outer periphery of the conductive component is provided with a plurality of flux parts respectively corresponding to the plurality of welding regions. Each of the flux parts is at least partially coated, along a perimetral direction of the conductive component, on the conductive component in a corresponding one of the welding regions.