Solar Cell Module Conductive Adhesive Interconnect

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing solar cell modules with back contact solar cells face challenges in achieving high output characteristics due to electrical resistivity and reliability issues in the connection between the solar cells and the wiring members, particularly at the interface of the electrodes and the resin adhesive layer.

Innovation Solution

A solar cell module design that incorporates a resin adhesive layer with conductive members embedded within, which dig into the finger parts and wiring, enhancing the contact area and reducing electrical resistivity, and a roughened surface treatment on the wiring and finger parts to facilitate better bonding and anchoring, using conductive members like metal or inorganic oxide particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a resin adhesive layer is used to bond the solar cell and wiring member, then ease of manufacture is improved, but electrical resistivity increases and reliability deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The resin adhesive layer is combined with conductive members (metal particles, inorganic oxide particles, or conductive paste) to create a composite adhesive layer that maintains the bonding properties of resin while adding electrical conductivity through the dispersed conductive particles, thereby reducing electrical resistivity and improving reliability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The electrical conductivity parameter of the adhesive layer is changed by incorporating conductive members with specific conductivity properties, transforming the insulating resin adhesive into a conductive composite adhesive that bridges the electrical connection between solar cells and wiring members

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If a resin adhesive layer is used to bond the solar cell and wiring member, then ease of manufacture is improved, but electrical resistivity increases

Engineering Contradiction:

Improveease of manufactureVSAvoidelectrical resistivity

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Conductive members serve as intermediary elements within the resin adhesive layer, creating conductive pathways that mediate the electrical connection between the solar cell electrodes and wiring members, reducing energy loss at the interface

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of energy

If the conductive member digs into the finger parts and wiring, then electrical resistivity is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrical resistivityVSAvoidmanufacturing precision

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The conductive members are incorporated into the resin adhesive layer before bonding, and the roughened surface structures are prepared in advance on the finger parts and wiring, so that when bonding occurs, the conductive members automatically dig into the roughened surfaces without requiring additional precision control during the bonding process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The roughened surface structures create porous or irregular surface topologies on the finger parts and wiring, allowing conductive members to mechanically interlock and dig into these surfaces, achieving reliable electrical contact while tolerating variations in manufacturing precision

Inventive Principle:

Principle #31Porous materials

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 improves output characteristics and reliability by reducing electrical resistivity and enhancing the anchoring effect, making electrical breakdown less likely, and allowing for improved stress distribution during bonding, thus enhancing the overall performance of the solar cell module.

Implementation Method 1

A portion of the conductive member digs into at least one of the finger parts and the wiring

Methodology Applied

Scientific EffectPhysical interlocking:

Implementation Method 2

The resin adhesive layer bonds the solar cell and the wiring member to each other

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS9911876B2Solar cell module

Publication Date: 2018.03.06 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

Disclosed is a solar cell module that comprises a solar cell including a first electrode and a second electrode on one main surface thereof, a wiring member electrically connected to the solar cell, and a resin adhesive layer bonding the solar cell and the wiring member to each other. Each of the first and second electrodes includes finger parts extending in one direction. The wiring member includes an insulating substrate, and a wiring disposed on the insulating substrate, and electrically connected to the finger parts of the first or second electrode. The resin adhesive layer includes an adhesive layer body made of a resin, and a conductive member disposed in the adhesive layer. A portion of the conductive member digs into at least one of the finger parts and the wiring.