Photovoltaic Panel Polymer Mask Cell Positioning
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Solution Overview
Problem
The high cost and fragility issues associated with custom photovoltaic cell design and the limitations of existing manufacturing methods, such as the CMS process, which can subject cells to mechanical stress and reduce contact areas, leading to instability and increased manufacturing costs.
Innovation Solution
A method involving a metal pattern on a printed circuit board with a soldermask and polymer masks to precisely position and bond photovoltaic cells without the need for a filling polymer, using an automated process that includes brazing and a bonding material to ensure secure and reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom photovoltaic cells are designed to meet specific needs, then the photovoltaic panel can be optimized for specific applications, but the manufacturing cost increases significantly
Solution Approach 1:
The patent segments the photovoltaic cell from the support structure by introducing a removable mounting frame and separate polymer layer. This allows standard cells to be used while achieving application-specific panel configurations through modular assembly rather than custom cell design.
Solution Approach 2:
The patent adds a vertical dimension to cell positioning by using a raised mounting frame structure. This allows standard cells to be positioned at optimal heights and angles for specific applications without modifying the cells themselves, resolving the contradiction between adaptability and manufacturing cost.
2Adaptability or versatility
If standard photovoltaic cells are cut to desired dimensions, then the panel can be customized, but the cells become more fragile and handling difficulty increases
Solution Approach 1:
The patent applies a polymer layer before final assembly that acts as a cushioning material. This polymer layer protects cut or small cells from mechanical damage during handling and installation, enabling customization without compromising cell integrity.
Solution Approach 2:
The patent uses a flexible polymer film as the mounting medium. This thin film can accommodate cells of various sizes and shapes while providing mechanical protection, allowing customization without increasing fragility.
3Ease of manufacture
If SMT process is used for assembling cut-down cells, then manufacturing is more economical, but the cells are subjected to mechanical stress that they cannot withstand
Solution Approach 1:
The patent changes the physical parameters of the assembly process by using a soft polymer mounting surface instead of rigid SMT fixtures. This allows automated placement while reducing mechanical stress on fragile cells, reconciling manufacturing economy with cell integrity.
Solution Approach 2:
The patent introduces a polymer layer as an intermediary between the cell and the rigid support structure. This mediator enables automated assembly processes while protecting the cell from mechanical stress, achieving both manufacturing economy and reliability.
4Reliability
If filling polymer is used to immobilize cells, then cells are protected and immobilized, but the process becomes more complex and costly
Solution Approach 1:
The patent extracts the filling polymer function from the assembly process by using a pre-formed polymer layer as the mounting surface. This eliminates the need for separate filling and curing operations, reducing process complexity while maintaining cell immobilization.
Solution Approach 2:
The patent prepares the polymer mounting layer in advance before cell placement. This preliminary action simplifies the overall process by eliminating the need for post-assembly filling operations, reducing both complexity and cost while ensuring proper cell immobilization.
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 method reduces manufacturing costs, enhances cell positioning and immobilization, and prevents mechanical stress on cells, resulting in a more reliable and cost-effective photovoltaic panel production process.
Implementation Method 1
a first mask in the form of a polymer film is applied to all or part of said solder mask to form a support for at least one photovoltaic cell
Implementation Method 2
a bonding operation is performed
Implementation Method 3
This step-cutting technique further reduces the risk of short circuits between the metallized circuits on and under the cell
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
According to the invention, the photovoltaic panel manufacturing process (1) is characterized in that it consists of the following steps: - A metallic pattern (4) is deposited on a printed circuit board (2); - At least one layer of solder mask (6) is applied to said board (2), leaving at least one area free of solder mask (7, 11); - A first mask (12) consisting of a polymer film is applied to all or part of said solder mask (6) to form a support for at least one photovoltaic cell (5); - A second mask (14), also consisting of a polymer film, is applied to all or part of said first mask (12), delimiting at least all or part of an implantation frame (15) for a photovoltaic cell (5);- At least one photovoltaic cell (5) is placed in said mounting frame (15) by aligning at least one connection zone (8, 8a) defined under said photovoltaic cell (5) with at least one connection zone (8, 8a) on said metallic circuit (4); - A binding operation is carried out.