PV Interconnect Joints Using Dual Adhesive Bonding Regions

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Solution Overview

Problem

Existing photovoltaic (PV) cell interconnect joints face challenges in achieving both high electrical conductivity and mechanical strength, which are crucial for efficient energy harvesting and durability, particularly under varying environmental conditions and manufacturing stresses.

Innovation Solution

The use of dual adhesive bonding regions with distinct materials and configurations, where one type is electrically conductive and the other provides mechanical strength, maximizes both electrical conductivity and mechanical strength of interconnect joints by optimizing the arrangement and properties of these regions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single adhesive bonding region is used to interconnect PV cells, then the manufacturing process is simple, but both electrical conductivity and mechanical strength cannot be simultaneously maximized

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidelectrical conductivity and mechanical strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bonding region is segmented into multiple distinct regions (first bonding region with conductive adhesive, second bonding region with non-conductive adhesive) along the interconnect, allowing each segment to perform its specialized function while collectively achieving both electrical conductivity and mechanical strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the bonding region are assigned different adhesive materials with different properties - the first bonding region uses electrically conductive adhesive for electrical connection, while the second bonding region uses non-conductive adhesive for mechanical reinforcement, optimizing local functionality at each position

Inventive Principle:

Principle #3Local quality

2Reliability

If multiple adhesive bonding regions are used to achieve both conductivity and strength, then interconnect quality improves, but manufacturing complexity increases

Engineering Contradiction:

Improveinterconnect qualityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The method applies adhesives in a predetermined sequence and pattern (first conductive adhesive, then non-conductive adhesive in specific regions) before final assembly, ensuring proper positioning and function of each bonding region while streamlining the manufacturing process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The interconnect joint structure is designed to perform multiple functions simultaneously - electrical conduction, mechanical bonding, and stress management - through the integrated multi-region adhesive system, reducing the need for separate components and processes

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional single adhesive system is used, then manufacturing is straightforward, but stress management and electrical conductivity are compromised

Engineering Contradiction:

Improvemanufacturing straightforwardnessVSAvoidstress management and electrical conductivity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The bonding system uses composite adhesive materials - combining electrically conductive adhesive and non-conductive adhesive in specific configurations - to achieve superior mechanical strength and electrical conductivity that neither material could provide alone

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The non-conductive adhesive regions are strategically positioned to provide mechanical reinforcement and stress distribution before electrical or environmental stresses can cause failure, preventing damage in advance while maintaining conductivity pathways

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 approach enhances the manufacturing rate and quality of PV cell strings and modules by ensuring greater stability and efficiency under mechanical and environmental stresses, improving the overall performance and longevity of PV systems.

Implementation Method 1

The first adhesive material is electrically conductive and the second adhesive material is not electrically conductive

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240014338A1Photovoltaic module interconnect joints

Publication Date: 2024.01.11 MAXEON SOLAR PTE LTD

AI summary

Photovoltaic (PV) cells that can be interconnected with improved interconnect joints to form PV cell strings and PV modules. The improved interconnect joints comprise at least two types of adhesive bonding regions to maximize both electrical conductivity and mechanical strength of interconnect joints coupling terminals of PV cells. The disclosed approaches to PV cell interconnection provide greater manufacturing rates and higher quality PV cell strings and PV modules.