Segmented Solar Cell Connecting Member Set for Alignment and Stress Reduction

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Solution Overview

Problem

Existing solar cell connection methods face challenges in achieving efficient electrical and mechanical connections between solar cells while maintaining high design characteristics and reducing defects such as warpage and cracks, especially when using a single connecting member that requires precise positioning and can lead to increased manufacturing time and defects.

Innovation Solution

A connecting member set comprising a first and second connecting member with planar portions that are layered and adhered using a conductive adhesive, featuring cut-out portions or openings to facilitate easy alignment and reduce stress, allowing for efficient electrical and mechanical connections between solar cells without visible electrodes on the light-receiving surface, enhancing workability and design aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single connecting member is used to connect solar cells, then the connection structure is simple, but the positioning precision is difficult to achieve and manufacturing time increases

Engineering Contradiction:

Improveconnection structureVSAvoidpositioning precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The connecting member is divided into a first connecting member and a second connecting member. The first connecting member connects to the first electrode of the first solar cell, while the second connecting member connects to the second electrode of the second solar cell. This segmentation allows each connecting member to be independently positioned and connected, improving positioning precision without significantly increasing overall structural complexity.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If a single connecting member is used, then the device structure is simple, but manufacturing time increases due to precise positioning requirements

Engineering Contradiction:

Improveconnection structureVSAvoidmanufacturing time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

By dividing the connecting member into two separate components, each can be pre-positioned and connected to solar cells independently. This reduces the time required for precise positioning during assembly, as each connecting member only needs to be positioned relative to one solar cell rather than coordinating multiple connections simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second connecting members can be pre-connected to their respective solar cells before final assembly. The planar portions are designed to be layered and adhered together, allowing preliminary preparation of connection points that simplifies the final assembly process and reduces manufacturing time.

Inventive Principle:

Principle #10Preliminary action

3Strength

If planar portions are layered and adhered without cut-out portions, then the connection is strong, but alignment is difficult and stress concentration occurs

Engineering Contradiction:

Improveconnection strengthVSAvoidalignment ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Cut-out portions are provided in the planar portions of the connecting members at specific locations. These localized modifications facilitate alignment during assembly by providing reference points or insertion features, while the surrounding areas maintain full adhesive bonding surface area to preserve connection strength. The cut-outs create local variations that aid positioning without compromising overall structural integrity.

Inventive Principle:

Principle #3Local quality

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 connecting member set enables efficient and reliable electrical connections between solar cells, reduces warpage and defects, and improves manufacturing efficiency by allowing easy alignment and adherence of planar portions, resulting in high-design solar cell strings and modules with improved power generation capabilities.

Implementation Method 1

the first planar portion and the second planar portion are layered on each other and electrically connected with each other

Methodology Applied

Scientific EffectConduction (electrical): Conduction (electrical)

Implementation Method 2

the first planar portion and the second planar portion are adhered to each other with an adhesive applied between an edge of the at least one of the cut-out portion or the opening formed in the first planar portion and the second planar portion exposed toward the first planar portion from the at least one of the cut-out portion or the opening

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS11362225B2Connection member set for solar battery cell, and solar cell string and solar cell module using same

Publication Date: 2022.06.14 KANEKA CORP

AI summary

A connecting member set includes a first connecting member connected to one of a pair of solar cells, and a second connecting member connected to the other solar cell. The first connecting member and the second connecting member have a first planar portion and a second planar portion, respectively. The first planar portion and the second planar portion are layered on each other and electrically connected with each other. The first planar portion has at least one of a cut-out portion or an opening through which the second planar portion is exposed toward the first planar portion when the first planar portion and the second planar portion are layered on each other.