Photovoltaic Module Asymmetric Interconnection Layout for Reduced Warping
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Solution Overview
Problem
Existing photovoltaic modules face high costs and poor performance due to the long length and high risk of twisting, warping, breaking, and cracking of conductive interconnection members in cell strings, resulting from uniform distances between electrode pads and solar cell edges.
Innovation Solution
The conductive interconnection member is designed to have a configuration where the sum of distances between specific solar cell edges and electrode pads (D1+D2) exceeds the sum of distances between other edges (D3+D4), allowing the start and end bonding points to be recessed inward, reducing the length of the interconnection member and minimizing the distance it needs to pass through, thereby reducing costs and the risk of twisting and warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive interconnection member is made longer to connect electrode pads uniformly, then the electrical connection is more stable, but the risk of twisting, warping, breaking, and cracking increases
Solution Approach 1:
The patent applies asymmetry by making the distances D1 and D2 greater than D3 and D4, creating an asymmetric arrangement where the interconnection member is shorter on critical paths. This reduces the length of the interconnection member where twisting and warping are most likely to occur, while still maintaining adequate electrical connection through the asymmetric distance distribution.
Solution Approach 2:
The patent changes the geometric parameters of the interconnection member arrangement by specifically defining that D1+D2 > D3+D4. This parameter change optimizes the balance between connection stability and mechanical integrity by adjusting the distances rather than uniformly extending the interconnection member.
2Length of moving object
If the length of the conductive interconnection member is reduced, then the cost and risk of twisting/warping are reduced, but the electrical connection distance may be insufficient
Solution Approach 1:
The asymmetric distance arrangement (D1+D2 > D3+D4) allows the interconnection member to be shorter overall while ensuring adequate connection distances are maintained in critical areas. The asymmetry enables optimized length distribution rather than uniform reduction.
Solution Approach 2:
The patent applies local quality by differentiating the distance requirements in different regions of the interconnection member. By setting specific distance relationships (D1, D2, D3, D4), the patent ensures adequate connection quality in local areas while allowing shorter lengths in other regions, achieving both cost reduction and reliability maintenance.
3Ease of manufacture
If uniform distances are used between electrode pads and solar cell edges, then the manufacturing process is simpler, but the interconnection member length increases causing higher costs and performance issues
Solution Approach 1:
The patent deliberately introduces asymmetry in the distance arrangement (D1+D2 > D3+D4) to optimize performance. While this deviates from uniform manufacturing, the asymmetric design is still manufacturable and provides significant performance benefits by reducing interconnection member length and associated risks.
Solution Approach 2:
The patent changes the manufacturing parameters from uniform distances to specific asymmetric distance relationships. This parameter change maintains manufacturing feasibility while dramatically improving module performance by reducing the length of conductive interconnection members and minimizing twisting, warping, breaking, and cracking risks.
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 length of the conductive interconnection member, lowering costs and minimizing the risk of twisting, warping, breaking, and cracking, while maintaining excellent performance of the photovoltaic module.
Implementation Method 1
the conductive interconnection member is electrically connected to the front electrode pads of the first solar cell and the back electrode pads of the second solar cell
Data Source
AI summary
This application provides a photovoltaic module, and relates to the field of photovoltaic technologies. The photovoltaic module includes a conductive interconnection member. The conductive interconnection member is electrically connected to front electrode pads of a first solar cell and back electrode pads of a second solar cell adjacent to the first solar cell. A distance between a first solar cell edge and the front electrode pad adjacent to the first solar cell edge is D1, a distance between a second solar cell edge and the front electrode pad adjacent to the second solar cell edge is D3, a distance between a fourth solar cell edge and the back electrode pad adjacent to the fourth solar cell edge is D2, a distance between a third solar cell edge and the back electrode pad adjacent to the third solar cell edge is D4. A sum of D1 and D2 is greater than a sum of D3 and D4.