Shingled Solar Cell Assembly Using Cleaved Overlapping Pieces
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Solution Overview
Problem
The manufacturing process of shingled solar cell arrangements is cumbersome and has low throughput and yield due to the presence of electrical contacts on the front surface of solar cells, which reduces the active area and module power.
Innovation Solution
An apparatus and method involving a cleaving station to separate solar cells into overlapping pieces, a storing station to store these pieces, and a transportation system to assemble them efficiently, using electrically conductive adhesives for connection, thereby increasing the active area and module power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical contacts (fingers and bus bars) are present on the front surface of solar cells, then electrical connectivity is achieved, but the active area is reduced and module power decreases
Solution Approach 1:
The solar cell is divided into multiple smaller solar cell pieces (e.g., 2x2 segmentation) that are arranged in a shingled configuration. This segmentation allows the electrical contacts to be positioned at the edges of each piece rather than covering the entire front surface, thereby preserving the active area while maintaining electrical connectivity through the overlapping arrangement and conductive adhesive.
Solution Approach 2:
The patent transitions from a planar arrangement of solar cells to a three-dimensional shingled configuration where solar cell pieces overlap in layers. This dimensional change allows electrical contacts to be distributed across multiple layers and positions, reducing their cumulative impact on the active area while maintaining electrical connectivity through the overlapping structure.
2Power
If shingled solar cell arrangement is assembled, then active area and module power are increased, but the manufacturing process becomes cumbersome with low throughput and yield
Solution Approach 1:
Solar cell pieces are pre-cut from complete solar cells before assembly into the shingled configuration. This preliminary action of segmentation allows for standardized, modular components that can be efficiently transported and assembled, improving throughput while maintaining the power benefits of the shingled arrangement.
Solution Approach 2:
Traditional mechanical assembly methods are replaced with a automated system using transportation means (conveyors) to move solar cell pieces between processing stations, and electrically conductive adhesives applied in controlled patterns to join pieces. This substitution of manual or complex mechanical assembly with automated material handling and precise adhesive application increases productivity and yield.
3Area of stationary object
If solar cells are separated into multiple pieces, then active area utilization is improved, but the manufacturing complexity increases
Solution Approach 1:
The solar cell is systematically divided into standardized smaller pieces using cleaving stations that create uniform segments. This regular segmentation pattern simplifies the overall manufacturing process by creating modular units that are easier to handle, transport, and assemble compared to irregular divisions, thereby reducing manufacturing complexity while maximizing active area utilization.
Solution Approach 2:
The cleaving station and transportation system are designed to handle multiple solar cell pieces simultaneously and perform multiple functions (cutting, sorting, transporting) in an integrated manner. This multi-functionality reduces the number of separate devices and process steps needed, thereby reducing manufacturing process complexity despite the increased segmentation.
Data Source
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AI summary
An apparatus includes a first processing line. The first processing line includes a cleaving station adapted for separating a solar cell into two or more solar cell pieces. The apparatus includes a second processing line. The second processing line includes a storing station adapted for storing a plurality of solar cell pieces. The second processing line includes a transportation system adapted for transporting a solar cell piece from the storing station to the first processing line.