Solar Cell Interconnect Structure With Discontinuous Contact
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Solution Overview
Problem
The existing photovoltaic module interconnection methods using soldering pads and PV ribbon protective films result in high costs, reduced light-receiving area, and hot spot issues, with complex manufacturing processes.
Innovation Solution
A solar cell structure with adhesive points and conductive components forming discontinuous contacts, eliminating the need for PV ribbon protective films and allowing low-temperature soldering, ensuring reliable electrical connections without shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering pads made of metallized paste are used in conventional busbars, then reliable electrical connection and sufficient tension are achieved, but light-receiving area is reduced and photoelectric conversion efficiency is limited
Solution Approach 1:
The patent extracts and removes the conventional busbar structure with metallized paste soldering pads from the solar cell surface. By eliminating these metal-based interconnection elements, the front surface area is fully available for light absorption, thereby resolving the contradiction between reliable electrical connection and maximum light-receiving area.
Solution Approach 2:
The patent introduces an adhesive-based intermediary system that replaces the traditional metallized paste. This adhesive layer serves as both the bonding medium for electrical connection and the mounting surface for PV ribbons, eliminating the need for separate soldering pads and thus preserving the light-receiving area while maintaining connection reliability.
2Reliability
If PV ribbon protective films are used to prevent hot spot melting, then hot spot damage is avoided, but manufacturing cost increases
Solution Approach 1:
The patent replaces the expensive PV ribbon protective film with a low-cost adhesive layer that inherently provides hot spot resistance. The adhesive serves as a sacrificial, disposable element that protects the PV ribbon during hot spot events without requiring additional protective film materials, thereby reducing manufacturing cost while maintaining reliability.
Solution Approach 2:
The adhesive layer performs multiple functions simultaneously: it bonds the PV ribbon to the solar cell, provides electrical insulation, and protects against hot spot damage. By consolidating these functions into a single material layer, the patent eliminates the need for separate protective films, reducing material cost and simplifying the manufacturing process.
3Reliability
If conventional soldering processes are used with metallized paste, then stable electrical connection is achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent replaces the thermal-based soldering process with an adhesive bonding process. Instead of using heat and metallized paste to create electrical connections, the system uses adhesive layers that bond mechanically and chemically at lower temperatures. This substitution eliminates complex soldering equipment and processes while maintaining connection stability.
Solution Approach 2:
The patent changes the fundamental parameters of the interconnection process: replacing high-temperature soldering with low-temperature adhesive bonding, and replacing metallized paste with adhesive materials. These parameter changes simplify the manufacturing process by eliminating the need for precise temperature control and complex soldering procedures while maintaining reliable electrical connections.
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 maintains the light-receiving area, avoids hot spots, reduces manufacturing costs, and simplifies the process by eliminating the need for protective films and complex stringing processes.
Implementation Method 1
an adhesive portion including a plurality of fixing adhesive points which are provided on a surface of the solar cell at intervals in a first direction; and a conductive component, a surface of the conductive component facing the solar cell being provided with a plurality of first contact regions and a plurality of second contact regions... The conductive component is fixed to the plurality of fixing adhesive points through the plurality of first contact regions
Data Source
AI summary
A solar cell structure includes: a solar cell; an adhesive portion including a plurality of fixing adhesive points provided on a surface of the solar cell at intervals in a first direction; and a conductive component, a surface of the conductive component facing the solar cell being provided with a plurality of first contact regions and a plurality of second contact regions arranged alternately in the first direction; the conductive component is fixed to the plurality of fixing adhesive points through the plurality of first contact regions, the plurality of fixing adhesive points electrically isolate the solar cell from the conductive component in the plurality of first contact regions, the conductive component is electrically in contact with a region on the solar cell other than the plurality of fixing adhesive points through the plurality of second contact regions, to form discontinuous contact between the conductive component and the solar cell.