Continuous PV Cell Stringing With Slit-Fold Foil Interconnects
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Solution Overview
Problem
Existing methods for photovoltaic cell stringing are slow, complex, and expensive, often requiring separate processes for collector-connector fabrication and cell stringing, which hinders efficient mass production.
Innovation Solution
A method involving a continuous process where a foil with electrically conductive wires is folded to create slits, allowing for efficient electrical connections between photovoltaic cells, using a foil with insulating material and conductive wires that change positions to ensure reliable and cost-effective stringing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate processes are used for collector-connector fabrication and cell stringing, then manufacturing precision can be maintained, but productivity decreases and device complexity increases
Solution Approach 1:
The patent combines the collector-connector fabrication and cell stringing processes into a single integrated continuous process. The foil with pre-applied conductive patterns serves as both the collector-connector substrate and the interconnection medium, eliminating the need for separate fabrication and assembly steps while maintaining manufacturing precision through controlled material deposition and positioning.
Solution Approach 2:
The patent implements a continuous manufacturing process where the foil moves continuously through the production line, allowing simultaneous fabrication of collector-connectors and stringing of photovoltaic cells. This continuous action eliminates interruptions between processes, significantly improving productivity while maintaining precision through consistent material handling and positioning.
2Productivity
If traditional cell stringing methods are used, then manufacturing precision can be maintained, but loss of time increases and productivity decreases
Solution Approach 1:
The patent applies conductive patterns to the foil in advance before the cell stringing process. This preliminary action prepares the interconnection pathways beforehand, allowing cells to be quickly attached and connected without time-consuming on-site fabrication steps, thereby reducing manufacturing time while maintaining connection precision.
3Ease of manufacture
If complex fabrication processes are used, then manufacturing precision can be maintained, but ease of manufacture decreases and production costs increase
Solution Approach 1:
The patent changes the physical state and properties of materials used in the process, such as using flexible foils that can be easily manipulated and positioned, and conductive inks or pastes that can be applied in continuous patterns. These parameter changes simplify the manufacturing process while ensuring reliable electrical connections through controlled material properties and deposition methods.
Data Source
AI summary
Example embodiments relate to methods for continuous photovoltaic cell stringing and photovoltaic cell assemblies. An example method includes providing a foil in a provision direction in a continuous manner. The method also includes cutting at least one slit into the foil along the provision direction. Additionally, the method includes creating at least one slit opening by folding open the foil at a location of the at least one slit. Further, the method includes providing at least one electrically conductive wire near a first surface of the foil along the provision direction aligned with the at least one slit opening in a continuous manner. Yet further, the method includes folding back the foil at the at least one slit opening after the electrically conductive wire provision such that the at least one electrically conductive wire changes its position.