Profiled Solder Ribbon Structure for Low-Shielding Solar Cells

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Solution Overview

Problem

Existing profiled solder ribbons have a significant shielding effect, affecting solar cell power generation performance and are prone to fragmentation during lamination due to lack of transition segments at joints.

Innovation Solution

A profiled solder ribbon design featuring a sequence of solder ribbon units with profiled, transition, and flat segments, including a triangular and rectangular shape configuration with rounded corners and internal copper core, and external platings to enhance light reflection and reduce copper consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If circular solder ribbons are used, then electrical conductivity is maintained, but shielding effect on cells increases affecting power generation performance

Engineering Contradiction:

Improvepower generation performanceVSAvoidshielding effect

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The solder ribbon is divided into multiple segments along its length, with each segment having a specific profiled shape (triangular cross-section) rather than a continuous circular shape. This segmentation allows light to pass through gaps between segments, reducing shielding effect while maintaining electrical conductivity through the copper core.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a two-dimensional circular cross-section to a three-dimensional profiled structure with triangular cross-sections arranged along the length. This dimensional change creates gaps that allow light transmission while maintaining the electrical conduction path through the copper material.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Use of energy by moving object

If profiled segments are located on edges of cells, then light utilization is improved, but cells are prone to fragmentation during lamination due to lack of transition segments

Engineering Contradiction:

Improvelight utilizationVSAvoidcell fragmentation resistance

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

Transition segments are pre-designed and positioned at the joints between profiled segments before the lamination process. These transition segments gradually change the profile from triangular to flat, preparing the structure to withstand lamination forces and prevent fragmentation during the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The transition segments act as cushioning elements that absorb and distribute the stress during lamination. By placing these gradual transition zones beforehand at critical joint locations, the structure is protected against sudden stress concentrations that would cause fragmentation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If sharp corners are present in profiled segments, then manufacturing is simplified, but stress concentration occurs leading to damage

Engineering Contradiction:

Improveprofiled segment fabricationVSAvoidresistance to damage

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Sharp corners in the profiled segments are replaced with rounded or curved transitions. This curvature eliminates stress concentration points while maintaining the overall triangular profiled shape. The rounded corners are easy to manufacture using standard forming processes and significantly improve the mechanical strength and damage resistance of the solder ribbon.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

Improves light utilization and reduces cell fragmentation by minimizing shielding and stress concentration, enhancing power generation performance and operational safety.

Implementation Method 1

the reflectivity of the first plating is 70-100%

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20260070161A1Profiled solder ribbon

Publication Date: 2026.03.12 SUZHOU MAXWELL TECH CO LTD

AI summary

Provided in the present disclosure is a profiled solder ribbon, which relates to the technical field of solar cell manufacturing. The profiled solder ribbon according to the present disclosure includes a plurality of solder ribbon units connected in sequence, and each solder ribbon unit includes a profiled segment, a first transition segment, a flat segment, and a second transition segment connected in sequence. The section of the profiled segment is in the shape formed by superimposing the triangle with the rectangle, so that light, when shining on an area of the triangle, can be reflected to a solar cell by the triangle to increase the light utilization. In addition, a lower part of a section of the profiled solder ribbon according to the present disclosure is rectangular, which can share part of the copper consumption required for electrical conduction, reduce the shielding of cells, and improve the light utilization.