Foil-like Solar Cell Connector with Insulating Carrier and Comb Structure
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Solution Overview
Problem
Existing methods for connecting solar cells to form modules face challenges such as the complexity of coating large film surfaces with copper, electrical short circuits, and the inefficiency of conductive adhesives, which affect the module's electrical and mechanical stability.
Innovation Solution
A method for manufacturing a foil-like electrical connector with a conductive layer and insulating surface layers, featuring recesses and perforations for precise positioning, and a comb structure for secure connections, which is wound into a roll for easy handling and application, ensuring effective electrical and mechanical series connections of solar cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large-surface film material is used to support copper coating for connecting solar cells, then the connector can cover the entire back side of the module, but coating and structuring the copper coating becomes very problematic and complex
Solution Approach 1:
The patent divides the large-surface connector into multiple smaller foil-like connectors, each corresponding to individual solar cells or small groups of cells. This segmentation simplifies the copper coating and structuring process for each smaller component while maintaining comprehensive coverage when assembled together in a matrix array configuration.
2Ease of manufacture
If conductive adhesives are used to connect cells to the backsheet, then the connection process is simplified, but the resistivity does not reach the low values of solders, affecting electrical performance
Solution Approach 1:
The patent combines both soldering and conductive adhesive methods into a single connector design. The foil-like connector includes contact points that can be soldered for low-resistance electrical connections, while also incorporating adhesive layers for mechanical bonding. This merging allows the system to achieve both the ease of adhesive application and the superior electrical conductivity of soldering.
3Device complexity
If a monolithic piece of film is used for the backsheet, then the structure is simple, but applying solder stop layers and avoiding electrical short circuits becomes technically problematic
Solution Approach 1:
The patent applies different properties to different regions of the connector. Insulating layers or solder stop layers are applied locally at specific contact points and edge areas where electrical isolation is needed, while other areas maintain conductivity for electrical connection. This local differentiation prevents short circuits without requiring a completely complex monolithic structure.
4Reliability
If multiple small connecting tabs are soldered onto edge pads, then electrical connections are established, but the process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple separate connecting tabs into a single integrated foil-like connector that can connect multiple solar cells simultaneously. This unified structure reduces the number of individual soldering operations required while maintaining reliable electrical connections at all contact points, thereby improving productivity without sacrificing connection quality.
Data Source
AI summary
In a method for manufacturing a foil-like electrical connector for connecting solar cells to form modules, an insulating carrier film sheet is initially provided in a width which essentially corresponds to the width of the solar cells to be connected. Furthermore, a conductive foil sheet having a width that is matched to the carrier film is provided. In addition, comb structures as subsequent electrical connection fingers are formed. The conductive foil sheet is positioned on the carrier film with the aid of pin-shaped extensions of a transport belt or a transport roller. The carrier film is subsequently joined to the conductive foil sheet, preferably via an adhesive bond. In the next step, an insulating cover film is applied, in particular laminated.