Segmented Solar Cell Module Layout for Narrow Gaps and Burr Avoidance
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Solution Overview
Problem
The existing methods for connecting solar cells using wiring members lead to increased panel size due to gaps between cells and potential shunt paths caused by burrs formed during laser cutting, which complicates the connection process and reduces output efficiency.
Innovation Solution
A solar cell module design where divided solar cells are connected using thin wire-shaped wiring members with a core layer and solder layer, positioned to minimize gaps and avoid contact with burrs, allowing for efficient electrical connection without increasing panel size and maintaining existing equipment compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If wiring members having a smaller width are used to reduce light losses, then the number of wiring members must be increased, but this causes the gap between neighboring solar cells to widen and the overall panel size to increase
Solution Approach 1:
The solar cell is divided into multiple segments along the long axis, with cut surfaces created by laser processing. These segmented cells are then connected using wiring members, allowing for optimized wiring configuration that reduces light loss while maintaining compact panel dimensions through precise segmentation and arrangement.
Solution Approach 2:
The invention utilizes the width dimension of the solar cell by dividing cells along the long axis and arranging them with specific orientations. This dimensional approach allows wiring members to be positioned optimally, reducing the need for excessive wiring while maintaining small panel footprint through clever spatial arrangement.
2Power
If the number of solar cells is increased to improve output, then the panel size increases, but this requires new production equipment and reduces price competitiveness
Solution Approach 1:
Mother solar cells are divided into multiple smaller cells along the long axis, allowing multiple cells to be arranged in series or parallel configurations within the same panel area. This segmentation enables increased output capacity without proportionally increasing panel size, maintaining compatibility with existing production equipment.
Solution Approach 2:
The divided solar cell structure and wiring configuration can be applied to existing production lines without requiring new equipment. The universal design allows the same manufacturing process to produce both traditional mother cells and the new divided cell configurations, maintaining price competitiveness while improving output.
3Ease of manufacture
If laser processing is used to divide solar cells, then division grooves are formed, but burrs are generated around the grooves causing shunt paths and reduced output
Solution Approach 1:
The harmful burrs generated during laser processing are removed through additional processing steps, such as mechanical removal or chemical etching, before the wiring members are attached. This extraction of the harmful element eliminates the shunt path risk while preserving the benefits of laser-based division grooves.
Solution Approach 2:
An intermediary processing step is introduced between laser grooving and final assembly to address the burr issue. This intermediate treatment, such as plasma cleaning or controlled etching, removes burrs without affecting the division groove quality, ensuring reliable electrical connections and maintaining output efficiency.
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 reduces the overall size of the solar panel, minimizes optical losses, and enhances output efficiency by reducing carrier movement distances and material costs, while preventing shunt paths and allowing for production using existing equipment.
Implementation Method 1
the process of dividing the solar cell into a plurality of solar cells irradiates a laser along an imaginary cutting line on a surface of the solar cell to form a division groove
Implementation Method 2
the surface is recrystallized, during this recrystallization, burrs are generated around the division groove
Implementation Method 3
a solder layer formed on surrounding a surface of the core layer
Data Source
AI summary
Discussed is a solar cell module including a plurality of solar cells including a first electrode and a second electrode, the plurality of solar cells being disposed along a first direction and a plurality of wiring members connected to the first electrode of a first solar cell and the second electrode of a second solar cell, wherein each of the plurality of solar cells includes a first side surface of one side in the first direction, a second side surface having a larger surface roughness than the first side surface on another side, and a protrusion formed adjacent to the second side surface, and wherein the first and second solar cells are disposed with a gap of approximately 0.5 mm to 1.5 mm, and the first side surface of the second solar cell and the second side surface of the first solar cell are disposed to face each other.