Photovoltaic Module Pad Layout to Prevent Dummy Bonding
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Solution Overview
Problem
Conventional photovoltaic modules experience poor reliability due to dummy bonding between the pad and the solder strip, leading to operational issues.
Innovation Solution
A photovoltaic module design that includes a pad with distinct parts connected via fasteners and a solder strip, where the fasteners are strategically placed to enhance the connection reliability, along with an adhesive film and light-transmitting member for improved structural integrity and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods between pad and solder strip are used, then manufacturing process is simple, but connection reliability is poor due to dummy bonding
Solution Approach 1:
The pad is divided into three distinct parts: a first part, a second part, and a third part. The first and third parts are positioned at opposite ends along the length direction of the solder strip, while the second part connects them. This segmentation allows for strategic placement of fasteners at multiple locations, improving connection reliability by preventing dummy bonding while maintaining a manageable structural complexity.
Solution Approach 2:
Different regions of the pad structure are designed with different widths along the length direction of the solder strip. The first and third parts have greater widths compared to the second part, creating local quality variations. This allows fasteners to be strategically positioned at the wider first and third parts where they can provide more effective anchoring, while the narrower second part maintains overall structural integrity.
2Reliability
If fasteners are strategically placed to enhance connection reliability, then dummy bonding is reduced, but manufacturing complexity increases
Solution Approach 1:
The pad structure is pre-designed with specific width variations at the first, second, and third parts before the fastening process. The first and third parts are formed with greater widths to accommodate fasteners, while the second part maintains a narrower width. This preliminary structural preparation simplifies the subsequent fastening operation, as fasteners can be directly placed at the predetermined locations without requiring complex alignment procedures during manufacturing.
3Stability of the object's composition
If pad width is optimized for fastener placement, then connection stability improves, but material usage increases
Solution Approach 1:
The pad structure implements local quality by varying the width at different sections. The first and third parts have greater widths specifically at the locations where fasteners need to be positioned, providing enhanced stability and anchoring. The second part, which connects the first and third parts, maintains a narrower width where fastener placement is not required. This localized width optimization ensures connection stability at critical points while minimizing overall material consumption compared to a uniformly wide pad design.
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
The solution significantly reduces the likelihood of dummy bonding, enhancing the operational reliability and service life of the photovoltaic module by providing more fixed connection points and symmetrical support for the solder strip, while also optimizing material usage and reducing the module's thickness.
Implementation Method 1
A photovoltaic module is a device that utilizes clean energy for power generation
Implementation Method 2
The adhesive films are arranged on two sides of the solar cell string along a thickness direction of the solar cell string
Data Source
AI summary
A photovoltaic module and a method for manufacturing photovoltaic module. The photovoltaic module includes a solar cell, a pad, fasteners, and a solder strip. The pad is arranged on the solar cell and includes first, second, and third parts, the first part is connected to the third part through the second part, and along a length direction of the solder strip, a width of the second part is less than a width of the first part and a width of the third part. The fasteners are arranged on a side of the first part facing away from the solar cell and a side of the third part facing away from the solar cell, the solder strip is provided between the fastener in the first part and the fastener in the third part, and the solder strip is connected to the pad through the fastener to form a solar cell string.