Multi-Row Pressing Needle Assembly for Grid Line Contact
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Solution Overview
Problem
The challenge in existing laser-induced metallization processes for photovoltaic cells is the high requirement for precise mounting accuracy of pressing needles, which can lead to positional deviations and failure to contact grid lines, resulting in electrical conduction issues.
Innovation Solution
A conductive assembly with multiple pressing needles arranged in rows, allowing for increased contact area and flexibility in alignment, ensuring that at least one needle can connect with the grid lines even with slight deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pressing needle is used to contact the grid line, then the device complexity is reduced, but the reliability of electrical contact deteriorates due to high mounting accuracy requirements and positional deviation during pressing
Solution Approach 1:
The single pressing needle is segmented into multiple pressing needles (at least two rows with multiple needles per row). Each needle can independently contact the grid line, so if one needle fails to contact due to positional deviation, other needles can still establish electrical contact. This segmentation transforms a single-point contact system into a multi-point contact system, significantly improving reliability while maintaining manageable structural complexity.
Solution Approach 2:
The contact area parameters are changed by arranging multiple pressing needles in rows and columns. The contact area is increased from a single needle tip to multiple needle tips distributed across the grid line. This parameter change allows the system to tolerate positional deviations while ensuring at least one needle maintains reliable electrical contact.
2Reliability
If high mounting accuracy is required for the pressing needle, then the electrical contact reliability improves, but the ease of manufacture and operation deteriorates due to stringent positioning requirements
Solution Approach 1:
By segmenting the contact function across multiple needles, the mounting accuracy requirement for each individual needle is relaxed. Instead of requiring one perfectly positioned needle, the system can accommodate variations in positioning for multiple needles, making manufacturing and assembly more feasible.
Solution Approach 2:
The multi-needle arrangement provides beforehand cushioning against positioning errors. Even if some needles are mispositioned during manufacturing or operation, the system is designed with redundant needles that can compensate for these errors and ensure reliable electrical contact.
3Ease of operation
If the pressing needle undergoes positional deviation during pressing, then the ease of operation improves with flexible pressing force application, but the reliability of electrical contact deteriorates due to failure to contact the grid line
Solution Approach 1:
The pressing function is segmented across multiple needles, allowing flexible application of pressing force while maintaining contact reliability. If one needle deviates during pressing, others can still maintain contact, providing operational flexibility without sacrificing reliability.
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 design reduces the probability of electrical failure by ensuring multiple pressing needles can engage with the grid lines, maintaining electrical contact and improving the metallization process efficiency.
Implementation Method 1
High-intensity laser irradiation is used to excite charge carriers in the photovoltaic cell
Implementation Method 2
triggering sintering to reduce a contact resistance between a metal and a semiconductor
Implementation Method 3
a deflection voltage is applied to the photovoltaic cell to separate carriers, forming a local current
Data Source
AI summary
Disclosed are a conductive assembly, an energizing apparatus, a laser-induced metallization device and a production line, solving a problem that if mounting accuracy of a pressing needle is not high or the pressing needle undergoes positional deviation during a pressing process, it is easy for the pressing needle to fail to contact a grid line, resulting in the pressing needle failing to conduct electricity. The conductive assembly includes a first mounting component and a plurality of pressing needles. The plurality of pressing needles are separately connected to the first mounting component. The pressing needle includes a contact portion, and the plurality of contact portions are arranged in a first direction and arranged in at least two rows in a direction perpendicular to the first direction.