Photovoltaic Testing Device with Flexible Flat Cable Interface
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Solution Overview
Problem
Current testing devices for photovoltaic devices face challenges in reliably contacting complex metallization designs, particularly back-contacting cells with multiple polarities on one side, requiring flexible and cost-effective solutions that can adapt to various contact structures without mechanical stress or shading, and ensuring uniform and reliable electrical connections.
Innovation Solution
A testing device featuring a printed circuit surface with electrically insulating material and flexible members that force the photovoltaic device against the printed circuit surface, providing uniform and protective contact while preventing mechanical damage and electrical short circuits, with the flexible member ensuring consistent force distribution and allowing for precise adaptation to different metallization patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring probes or bent wires are used to contact photovoltaic devices, then electrical connection can be established, but the contact structure becomes complex and requires delicate assembly steps
Solution Approach 1:
The patent extracts the complex spring probe or bent wire structures and replaces them with a simplified flat cable assembly. The flat cable with contact elements directly contacts the photovoltaic device, eliminating the need for delicate spring mechanisms or bent wire configurations, thus reducing assembly complexity while maintaining electrical connection reliability
Solution Approach 2:
The patent employs a flat cable with flexible characteristics to establish electrical contact. This thin film-like structure can adapt to different photovoltaic device configurations without requiring complex rigid support structures, simplifying the overall contacting mechanism while ensuring reliable electrical connection
2Reliability
If multiple spring probes are aligned over bus bars, then electrical contact is achieved, but the contact area cross section becomes very small compared to ribbons
Solution Approach 1:
The patent merges multiple contact elements onto a single flat cable structure, combining what would traditionally require multiple separate spring probes into one integrated assembly. This increases the effective contact area cross-section to match ribbon-like dimensions while maintaining reliable electrical contact through the distributed contact elements on the flat cable
3Reliability
If needle pins are used to contact bus bars, then electrical connection is established, but the needle pins are very delicate and easily damaged
Solution Approach 1:
The patent replaces delicate needle pins with contact elements mounted on a flexible flat cable. This thin film-like structure provides inherent mechanical strength and durability while maintaining the ability to establish reliable electrical connections, eliminating the fragility issue of needle pins
Solution Approach 2:
The flat cable with contact elements serves multiple functions: it provides mechanical support, establishes electrical contact, and offers durability. This multi-functional design replaces the single-function delicate needle pin, improving both strength and connection reliability simultaneously
4Reliability
If an array of spring probes is used for each bus bar, then electrical contact is achieved, but the assembly requires many delicate assembly steps
Solution Approach 1:
The patent combines multiple spring probe assemblies into a single flat cable structure with integrated contact elements. This merging reduces the number of separate assembly steps required, as the flat cable can be installed as one unit rather than requiring individual alignment and assembly of multiple spring probe arrays, thereby improving ease of manufacture while maintaining electrical contact reliability
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 enables reliable and uniform electrical contact with minimal mechanical stress, supporting various metallization designs, and allows for precise testing of photovoltaic devices with reduced shading and improved thermal contact, ensuring accurate measurements and cost-effective manufacturing.
Implementation Method 1
forcing means for forcing the electrical interface and the photovoltaic device against each other when the photovoltaic device is received by the support
Implementation Method 2
the electrical interface comprises a printed circuit surface with exposed electrical contacts formed by printed conducting structures on electrically insulating material
Data Source
Figure 1~2
Figure 3
Figure 4~7
AI summary
The invention relates to testing devices (1 ) for testing a photovoltaic device (2), particularly a solar cell element, a solar cell and/or a string of solar cells, having electrical contacts (3) on at least one of its flat surfaces, the testing device (1) comprising: - a support (4) having a receiving surface (5) for receiving the photovoltaic device (2), - at Ieast one measurement device (6), - at Ieast one electrical interface (7) having exposed electrical contacts (8) for abutting against at Ieast one electrical contact (3) of the photovoltaic device (1), in order to establish a temporary electrical connection, wherein the electrical interface (7) is connected to the measurement device (6), The invention also relates to a method for testing a photovoltaic device (2),