Shingled Solar Cell Strip Bonding Without Busbars or Ribbons
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Solution Overview
Problem
Existing solar cell manufacturing technologies face issues such as defects and burrs in strip cuts, waste of busbar material, reduced annealing effect, increased ribbon breakage risk, and power loss due to ribbon shading, necessitating improved methods for connecting solar cell strips efficiently.
Innovation Solution
A shingled solar cell panel design that uses a conductive adhesive to electrically connect overlapping strips without busbars, allowing precise control of overlapping intervals and reducing contact resistance, while using wires for string connections to minimize power loss and enhance mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used to connect solar cell strips, then electrical connection is achieved, but material waste and production cost increase
Solution Approach 1:
The patent extracts and eliminates the busbar component from the solar cell connection system. Instead of using traditional busbars to connect solar cell strips, the invention directly bonds the strips together through edge-to-edge contact, removing the unnecessary intermediate material and reducing production costs while maintaining electrical connectivity.
Solution Approach 2:
The patent replaces expensive busbar materials with a simpler, more cost-effective bonding approach. By using direct edge-to-edge contact with minimal bonding material, the system achieves electrical connection without consuming valuable busbar materials, effectively substituting expensive components with cheaper alternatives.
2Reliability
If ribbons are used for string connections, then electrical connection is achieved, but power loss due to shading increases
Solution Approach 1:
The patent removes the ribbon component from the string connection system. By eliminating ribbons that cause shading, the invention allows sunlight to reach more solar cell surfaces, reducing energy loss while maintaining electrical connectivity through alternative bonding methods.
Solution Approach 2:
The patent applies local bonding only where necessary for electrical connection (at the edges of solar cell strips) rather than using broad ribbons that cover large areas. This localized approach maintains electrical connectivity while minimizing the shading effect and preserving light absorption in the remaining areas.
3Productivity
If conventional cutting methods are used to divide solar cells, then strips are produced, but defects and burrs occur in cut portions
Solution Approach 1:
The patent changes the cutting parameters and methods to produce high-quality strip edges. By optimizing cutting depth, speed, and method (such as using diamond wire cutting or precision sawing), the invention achieves clean cuts without burrs or defects, ensuring proper edge-to-edge contact for electrical connection.
4Reliability
If overlapping strips are used to form strings, then electrical connection is achieved, but contact resistance increases
Solution Approach 1:
Instead of overlapping strips to achieve electrical connection, the patent inverts the approach by using edge-to-edge contact. The strips are positioned with their edges touching directly, eliminating the overlapping configuration that causes increased contact resistance and improving electrical conductivity.
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 reduces material waste, lowers production costs, enhances output efficiency by minimizing shading, and improves mechanical strength between strings, achieving higher solar cell integration and output.
Implementation Method 1
uses a conductive adhesive to electrically connect overlapping strips
Implementation Method 2
the surface of a solar cell is formed at a desired position by using a high-power laser beam
Data Source
AI summary
The present invention relates to a shingled solar cell panel for producing a string in which a plurality of strips are partially overlapped with each other, and for electrically connecting the string and the string, and a method for producing the same, the method comprises providing a wafer made of a HIT in which a plurality of conductive layers are formed on upper and lower portions thereof, respectively, forming an adhesive layer by applying a conductive adhesive on the upper conductive layer, dividing the wafer on which the adhesive layer is formed into a plurality of strips, forming a string by overlapping a lower conductive layer of another strip on an area where an adhesive layer is provided among the divided strips. Accordingly, the upper conductive layer and the lower conductive layer of each of the plurality of strips can be configured to be electrically bonded via only the adhesive layer to provide a shingled solar cell panel at low cost.