Solar Cell Array Cross-Connection With Conductive Adhesive Tape
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Solution Overview
Problem
The cross-connection of crystalline solar cell arrays using copper strips is laborious and can cause damage due to heat input, leading to inefficient and potentially harmful soldering processes.
Innovation Solution
Utilizing electrically conductive adhesive tape as cross-connectors to simplify and protect the cross-connection process, eliminating the need for soldering and reducing mechanical effort, while allowing for faster and more efficient production of solar panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper strips with soldering are used for cross-connection, then reliable electrical connection is achieved, but the process becomes laborious and time-consuming
Solution Approach 1:
The patent replaces the mechanical soldering process with a chemical bonding process using electrically conductive adhesive tape. The adhesive tape bonds directly to the solar cell contacts through adhesive chemistry, eliminating the need for mechanical soldering operations while maintaining reliable electrical connection. This substitution transforms a labor-intensive mechanical process into a simpler chemical bonding process that can be applied more rapidly.
Solution Approach 2:
The invention changes the bonding mechanism parameter from thermal-mechanical (soldering requiring heat and pressure) to chemical-adhesive (tape bonding requiring only adhesive contact). This parameter change allows for faster application since the adhesive tape can be applied without the time-consuming heating and cooling cycles required for soldering, thereby improving productivity while maintaining connection reliability.
2Reliability
If copper strips with soldering are used for cross-connection, then electrical connection is established, but heat input damages the solar cells
Solution Approach 1:
The patent replaces the thermal soldering process with a cold chemical bonding process using electrically conductive adhesive tape. The adhesive tape creates reliable electrical connections through chemical adhesion without introducing thermal energy to the solar cells. This substitution eliminates the harmful heat effect while preserving the essential function of establishing reliable electrical connections between solar cell strings.
Solution Approach 2:
The invention converts the potentially harmful thermal process into a beneficial cold process. By using electrically conductive adhesive tape, the patent transforms the connection method from one that introduces harmful heat (soldering) to one that operates at ambient temperature, thereby protecting the solar cells from thermal damage while still achieving reliable electrical connectivity.
3Reliability
If copper strips are used for cross-connection, then electrical connection is achieved, but mechanical effort and complexity increase
Solution Approach 1:
The patent replaces the complex mechanical soldering system with a simple adhesive tape application system. Instead of requiring soldering irons, heat control mechanisms, and skilled manual dexterity for precise soldering operations, the invention uses electrically conductive adhesive tape that can be simply applied and bonded to the solar cell contacts. This substitution dramatically reduces device complexity and process complexity while maintaining reliable electrical connections.
Solution Approach 2:
The invention employs disposable electrically conductive adhesive tape instead of reusable copper strips that require soldering. The tape is a single-use component that is applied directly and discarded after bonding, eliminating the need for complex reusable soldering equipment and the skilled labor required to operate it. This approach reduces device complexity and makes the cross-connection process more accessible and simpler to perform.
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 method enables efficient, economical, and gentle cross-connection of solar cell arrays, protecting the solar cells and reducing waste, with the potential for automated implementation and improved performance under partial shading conditions.
Implementation Method 1
at least one cross-connector made of electrically conductive adhesive tape is used for cross-connecting the solar cell array
Data Source
AI summary
In the technical field of solar panel (1) manufacturing, a method is proposed for cross-connecting a solar cell array (2) of crystalline solar cells (3), in which at least one cross-connector (4, 9) of electrically conductive adhesive tape (5, 7) is used for cross-connection.