Metal Foil Pattern Layered Body for Solar Cell Modules

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Solution Overview

Problem

Conventional methods for manufacturing metal foil pattern layered bodies for solar cell modules face challenges such as difficulty in patterning large-scale metal foils, high costs due to extensive use of chemical etching solutions, and issues with durability and reliability, including displacement of insulating layers and short-circuiting of electroconductive members.

Innovation Solution

A metal foil pattern layered body is created with a base member, a metal foil having a pattern formed by opening and metal portions, and protuberances at the boundary between the opening and metal portions, which are bent towards the base member and anchored in an adhesive layer, preventing removal and improving durability and reliability by enhancing light utilization efficiency and preventing short-circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If chemical etching is used to form metal foil patterns, then the metal foil can be patterned, but the manufacturing cost increases due to extensive use of chemical etching solutions

Engineering Contradiction:

Improvemetal foil patterning capabilityVSAvoidchemical etching solution consumption

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces chemical etching with a mechanical cutting method using a cutting blade to form patterns in the metal foil. The cutting blade physically cuts the metal foil along desired pattern lines, eliminating the need for chemical etchants and their associated disposal costs while achieving precise pattern formation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the harmful chemical etching process from the manufacturing system, replacing it with a mechanical cutting approach. This extraction eliminates the need for chemical solutions and their environmental management requirements while maintaining pattern formation capability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Device complexity

If the metal foil pattern is directly placed on the base member, then the structure is simple, but the metal foil pattern can be removed reducing durability

Engineering Contradiction:

Improvelayered structure simplicityVSAvoidmetal foil pattern retention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies adhesive to the base member surface before placing the metal foil pattern, creating a pre-established bonding interface. This preliminary adhesive application ensures that when the metal foil pattern is positioned and pressed onto the base member, it achieves immediate and durable adhesion, preventing removal or displacement during subsequent manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a composite structure consisting of the base member, adhesive layer, and metal foil pattern bonded together. This multi-material composite provides both structural simplicity and enhanced reliability, as the adhesive layer acts as a bonding interface that securely attaches the metal foil pattern to the base member while maintaining overall structural integrity.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If the edge face of the metal foil is vertical to the base member, then the manufacturing is easier, but the insulating layer can be removed or displaced reducing reliability

Engineering Contradiction:

Improvemetal foil edge formationVSAvoidinsulating layer stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the edge face of the metal foil from a vertical straight edge to an inclined surface that angles toward the base member. This curved or angled geometry creates a mechanical interlock with the insulating layer, preventing its removal or displacement. The inclined surface allows the insulating layer to rest against it at an angle, providing stability while maintaining ease of manufacture through standard cutting techniques.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Reliability

If wiring members overlap the light-receiving face of solar cells, then electrical connection is achieved, but the area efficiency of photoelectric conversion is degraded

Engineering Contradiction:

Improveelectrical connection capabilityVSAvoidphotoelectric conversion efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent inverts the conventional wiring arrangement by placing all electrical connection elements (metal foil patterns, adhesive layers, insulating layers) on the back face of the solar cell rather than having wiring members overlap the front light-receiving face. This inversion allows the entire front surface to be dedicated to light absorption and photoelectric conversion, eliminating energy loss while maintaining electrical connection functionality through the inverted back-contact architecture.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS10672928B2Metal foil pattern layered body, metal foil layered body, metal foil multi-layer substrate, solar cell module, and method of manufacturing metal foil pattern layered body

Publication Date: 2020.06.02 ENDURANCE SOLAR SOLUTIONS INC

AI summary

A metal foil pattern layered body of the invention includes a base member; a metal foil including a metal pattern formed by an opening and a metal portion; and a protuberance provided at the metal foil and at a boundary between the opening and the metal portion.