Reciprocal Metal Wire Solar Cell Array Design
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Solution Overview
Problem
Existing solar cell technologies face challenges in increasing the number of conductive wires without increasing costs and reducing photoelectric conversion efficiency, due to limitations in manufacturing processes and equipment capabilities, as well as issues with welding and sealing caused by the use of transparent films.
Innovation Solution
A solar cell array design that uses metal wires extending reciprocally between cells to form conductive wires, which are welded with secondary grid lines, allowing for a higher number of conductive wires without the limitations of space and equipment constraints, and maintaining reliable connections and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of conductive wires is increased to reduce costs and improve photoelectric conversion efficiency, then manufacturing complexity and equipment constraints increase
Solution Approach 1:
The patent divides the conductive wire structure into primary grid lines and secondary grid lines, with the metal wire extending reciprocally between cells to form multiple conductive wires. This segmentation allows for increased number of conductive wires while maintaining manageable manufacturing complexity through modular assembly of cells and wires.
Solution Approach 2:
The metal wire is nested within the cell array structure, extending reciprocally between adjacent cells and forming conductive wires that are integrated into the module architecture. This nesting approach allows multiple conductive wires to be accommodated within the existing cell layout without requiring separate manufacturing equipment for each wire.
2Quantity of substance
If thinner metal wires are used to allow more wires, then welding reliability decreases
Solution Approach 1:
The patent specifies optimal parameters for the metal wire diameter (0.1-0.5mm) and the number of conductive wires (n) based on the cell dimensions (A×B), using the formula y=4.0533X−1.28/1562*A*B where y−y×20%≤n≤y+y×20%. These parameter optimizations ensure that sufficient numbers of conductive wires can be implemented while maintaining welding reliability through appropriately sized wires that are not too thin to weld.
3Quantity of substance
If more conductive wires are added, then space constraints and equipment limitations are exceeded
Solution Approach 1:
The metal wire extends reciprocally between the front surface and back surface of adjacent cells, utilizing the third dimension (depth/height) rather than only the two-dimensional cell surface. This allows conductive wires to be formed vertically through the cell thickness, enabling more wires to be accommodated within the same cell area without exceeding space constraints.
Solution Approach 2:
The metal wire serves multiple functions: it acts as both the primary grid line on one cell and the secondary grid line on the adjacent cell, and simultaneously forms multiple conductive wires through its reciprocal extension. This multi-functionality allows a single wire structure to accomplish what would otherwise require multiple separate components, avoiding equipment limitations.
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 design enables a significant increase in the number of conductive wires, reducing costs and improving photoelectric conversion efficiency while ensuring reliable connections and good sealability, making the technology suitable for mass production.
Implementation Method 1
The conductive wires are welded with the secondary grid lines by a welding layer
Data Source
AI summary
A solar cell array comprises a plurality of cells, adjacent cells connected by a metal wire. At least one metal wire extends reciprocally between a surface of a first cell and a surface of a second cell adjacent to the first cell to form a plurality of conductive wires. The number of the conductive wires is n, y−y×20%≤n≤y+y×20%, in which n is an integer and y=4.0533X−1.28/1562*A*B, in which X is a diameter value of the metal wire with mm as a unit, 0.1≤X≤0.5, A and B representing length and width of the cell with mm as the unit. The cells comprise secondary grid lines disposed on front surfaces thereof. The conductive wires are welded with the secondary grid lines by a welding layer.