Shingled Solar Module Cell Sheet Splitting and Contact Design
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Solution Overview
Problem
Existing shingled solar modules face challenges such as weak interconnections, high manufacturing costs, environmental sensitivity, and potential for short circuits due to the use of electrically conductive adhesives, which are prone to degradation and overflow issues.
Innovation Solution
A large cell sheet is designed for easy splitting into solar cells, featuring an electrically-conductive contact area for direct primary and secondary grid line contact and a bonding area for a non-conductive adhesive, optimizing production and performance by reducing the need for silver paste and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically conductive adhesive is used to interconnect cut cells, then electrical connection is achieved, but the adhesive is prone to degradation and overflow under environmental factors
Solution Approach 1:
The patent divides the cell sheet into multiple independent units with distinct functional zones: a bonding area for adhesive application and an electrically conductive contact area for direct grid line contact. This segmentation allows the adhesive to be confined to specific regions where it bonds cells together, while the conductive contact areas provide reliable electrical connection through direct contact between grid lines, preventing adhesive degradation from affecting electrical performance.
Solution Approach 2:
The patent introduces a non-conductive adhesive as an intermediary material to bond solar cells together mechanically, while the electrical connection is mediated through direct contact between the grid lines of adjacent cells at the electrically conductive contact area. This separation of mechanical bonding and electrical conduction functions eliminates the problem of conductive adhesive degradation.
2Reliability
If metal welding ribbon is used for interconnection, then electrical connection is achieved, but stress damage occurs to cell interconnection locations
Solution Approach 1:
The patent replaces the mechanical welding ribbon system with a combination of adhesive bonding and direct grid line contact. The non-conductive adhesive provides mechanical bonding without the stress concentration issues of metal welding ribbons, while the grid lines themselves provide the electrical connection through direct contact at the electrically conductive contact area, eliminating the need for separate conductive interconnection elements.
3Ease of manufacture
If conventional solar module design is used, then manufacturing is straightforward, but inter-cell gap areas are not fully utilized for power generation
Solution Approach 1:
The patent merges the functions of cell interconnection and power generation by designing the cell sheet units to overlap in a shingled configuration. The electrically conductive contact area is positioned at the overlapping edge of adjacent units, allowing the inter-cell gap areas to be utilized for both mechanical bonding via adhesive and electrical connection through direct grid line contact, thereby increasing energy density without complicating the manufacturing process.
4Productivity
If large cell sheet is designed for easy splitting, then production efficiency is improved, but precise control of contact areas is required
Solution Approach 1:
The patent applies local quality by creating distinct zones within the cell sheet: a bonding area with adhesive for mechanical attachment and an electrically conductive contact area with direct grid line contact for electrical connection. This local differentiation allows the sheet to be easily split into units while ensuring that the contact areas are precisely positioned at the overlapping edges, maintaining manufacturing precision through functional zoning rather than requiring uniform precision across the entire sheet.
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 solution enhances the reliability and efficiency of shingled solar modules by ensuring robust electrical connections, reducing material costs, and improving resistance to environmental factors, while also simplifying the manufacturing process.
Implementation Method 1
a light-transmitting electrically-conductive film disposed on a top surface and a bottom surface of the central layer
Implementation Method 2
a base sheet... disposed on a substrate
Data Source
AI summary
The present disclosure relates to large cell sheets, solar cells, shingled solar modules, and manufacturing method thereof. A top surface of a boundary portion of units of the large cell sheet is divided into a cutting area, top surface bonding areas and top surface electrically-conductive contact areas. The cutting area is configured in a way that the large cell sheet can be cut along the cutting area; the top surface bonding areas and the top surface electrically-conductive contact areas are provided alternately, the cutting area and the top surface electrically-conductive contact areas are formed as an overlapping edge of the solar cell, and after the splitting of the large cell sheet, the top surface electrically-conductive contact areas can directly contact the bottom surface of another solar cell to achieve electrically-conductive connection. The large cell sheet according to the present disclosure can be split conveniently, and the individual solar cells are provided with dedicated bonding areas and electrically-conductive contact areas. Such an arrangement can optimize the production process and use performance of the solar cells.