Solar Cell Assembly Solid State Bonding Pad
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Solution Overview
Problem
Conventional solar cell assemblies face challenges in achieving reliable electric contacting, efficient thermal conductivity, and long-term reliability due to complex and costly processing steps, including poor thermal conductivity and the risk of galvanic elements, especially in concentrator solar photovoltaic applications.
Innovation Solution
A method for manufacturing a solar cell assembly using a solid state connection between a bonding pad and a cooling substrate without additional materials or insulation layers, facilitated by planar joining or attachment, utilizing techniques like laser welding, ultrasonic welding, or sintering, which reduces the need for expensive contact materials and minimizes galvanic risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If selective noble metal deposition is used to contact the back side of the solar cell to the substrate, then reliable electric contacting is achieved, but the processing becomes tedious, time-consuming and expensive
Solution Approach 1:
The bonding pad and cooling substrate are merged into a single integrated component made of aluminum or aluminum alloy. This eliminates the need for separate noble metal deposition layers while providing both electrical contact and thermal management functions through the direct solid state connection between the solar cell and the integrated bonding pad-cooling substrate assembly.
Solution Approach 2:
The bonding pad is designed to serve multiple functions simultaneously: it provides electrical contact to the solar cell back side, acts as a thermal management component (cooling substrate), and serves as a mechanical bonding interface. This multi-functionality eliminates the need for separate noble metal contact layers and insulating material elements.
2Reliability
If electrically isolating material elements are provided to separate contact regions, then electrical isolation is achieved, but thermal conductivity deteriorates due to poor thermal connection
Solution Approach 1:
Instead of using planar insulating material elements that create thermal barriers, the patent uses the vertical dimension (thickness variation) of the bonding pad to achieve electrical isolation. The bonding pad extends beyond the solar cell contact regions in specific areas, creating natural electrical isolation through geometric configuration rather than through insulating materials, thereby maintaining continuous thermal pathways.
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 approach enhances the reliability and lifetime of the solar cell assembly by providing a direct and efficient thermal and electrical connection, reduces production costs, and simplifies the manufacturing process, while avoiding the formation of galvanic elements that can degrade performance.
Implementation Method 1
utilizing techniques like laser welding, ultrasonic welding, or sintering
Implementation Method 2
utilizing techniques like laser welding, ultrasonic welding, or sintering
Implementation Method 3
utilizing techniques like laser welding, ultrasonic welding, or sintering
Implementation Method 4
The solar cell assembly (SCA) may particularly provide environmental protection, heat dissipation and electrical connectivity to the solar cell
Data Source
AI summary
The present invention relates to a solar cell assembly, comprising a solar cell attached to a bonding pad and a cooling substrate and wherein the bonding pad and the cooling substrate are joined to each other in a planar and flush manner such that the bonding pad and the cooling substrate are connected to each other in the form of a solid state connection. The invention further relates to a solar cell assembly that includes a solar cell attached to a bonding pad and a cooling substrate and wherein the bonding pad is attached on a surface of the cooling substrate such that the bonding pad and the cooling substrate are connected to each other in the form of a solid state connection. Also, a method for manufacture of such solar cell assemblies is provided.