Reflective Solder Strip Geometry for Higher Solar Module Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solder strips for photovoltaic modules face inefficiencies in current collection and power output due to suboptimal design, particularly in light reflection and solder layer agglomeration during soldering, which affects the utilization of reflected light and module performance.
Innovation Solution
A solder strip with a cross-sectional design featuring a base portion and a reflective portion with acute angles greater than 42.5°, a copper substrate, and a solder layer, which enhances light reflection and prevents solder layer agglomeration by incorporating specific edge structures and dimensions, ensuring effective photoelectric conversion and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional rectangular solder strips are used, then manufacturing is simple, but light reflection utilization is poor and power output is limited
Solution Approach 1:
The invention transitions from a conventional rectangular cross-section to a triangular cross-section with specific angle requirements (42.5° to 90°). This dimensional change optimizes the reflective surface geometry to improve light reflection utilization and increase power output by 1W per module, while maintaining manufacturing feasibility through precise angular control.
Solution Approach 2:
The invention specifies precise parameter ranges for the triangular cross-section, particularly the side angles between 42.5° and 90°, and height-to-width ratio between 60% to 80%. These parameter optimizations enhance light reflection efficiency and prevent solder layer agglomeration, directly improving power output while maintaining structural integrity.
2Power
If solder strip height is increased to improve light reflection, then reflection efficiency improves, but solder layer agglomeration occurs during soldering
Solution Approach 1:
The invention optimizes the height-to-width ratio parameter to 60%-80% and controls the absolute height to be ≤0.3mm. This parameter optimization achieves the optimal balance between light reflection efficiency and preventing solder layer agglomeration during the soldering process, ensuring both power output and reliability.
Solution Approach 2:
The specific angular design (42.5° to 90°) of the triangular cross-section preliminarily prevents solder layer agglomeration by creating optimal flow paths during soldering. The geometric configuration anticipates and counteracts the agglomeration tendency before it occurs, ensuring uniform solder distribution.
3Power
If precise angular control is implemented to optimize light reflection, then power output increases, but manufacturing precision requirements increase
Solution Approach 1:
The invention defines a practical parameter range for side angles (42.5° to 90°) rather than requiring a single precise value. This range-based specification maintains manufacturing feasibility while achieving optimal light reflection efficiency and power output enhancement of 1W per module.
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 designed solder strip improves light reflection and utilization, increases power output by 1 W per module, reduces material costs, and prevents solder layer agglomeration, leading to enhanced efficiency and reliability in photovoltaic module performance.
Implementation Method 1
A solder strip with a cross-sectional design featuring a base portion and a reflective portion with acute angles greater than 42.5°, which enhances light reflection and utilization
Data Source
AI summary
Provided is a solder strip. A cross section of the solder strip includes a base portion and a reflective portion arranged above the base portion. The reflective portion includes a top edge, a first side edge and a second side edge. A first angle is formed between the first side edge and an extension line of the top edge. A second angle is formed between the second side edge and the extension line of the top edge. The first angle and the second angle are greater than 42.5°.