Solar Cell Module Connection Electrode Projections
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Solution Overview
Problem
The existing methods for connecting solar cells through wiring members face challenges in maintaining a favorable electrical connection due to displacement of conductive particles caused by temperature changes and stress from the sealant, leading to potential disruptions in the electrical connection.
Innovation Solution
The solar cell module incorporates connection electrodes with projections that directly contact the wiring member, using a resin adhesive with conductive particles, and a mechanical connection that allows the projections to bite into the wiring member, ensuring a stable electrical and mechanical connection even under temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive particles are used in resin adhesive to establish electrical connection, then electrical connection is established, but conductive particles displace due to temperature change and sealant stress causing connection failure
Solution Approach 1:
The patent introduces an intermediary structure (protrusions on connection electrode and corresponding recesses on wiring member) that mediates between the conductive particles and the external stress from sealant expansion. This mechanical interlocking structure protects the conductive particles from displacement while maintaining electrical connection, resolving the contradiction between connection reliability and particle position stability.
Solution Approach 2:
The patent creates a composite connection structure combining mechanical interlocking (protrusions and recesses), adhesive bonding (resin adhesive), and conductive elements (conductive particles). This composite approach distributes stress across multiple mechanisms, preventing conductive particle displacement while maintaining reliable electrical connection under thermal cycling conditions.
2Reliability
If sealant with high linear expansion coefficient is used to seal solar cells, then sealing performance is improved, but stress on wiring member increases causing conductive particle displacement
Solution Approach 1:
The mechanical interlocking structure (protrusions and recesses) acts as an intermediary that absorbs and distributes the stress generated by sealant expansion. This structure protects the wiring member and conductive particles from direct stress transmission, allowing high-expansion sealant to be used for improved sealing without causing particle displacement.
3Reliability
If wiring member is soldered to connection electrode, then strong electrical connection is established, but temperature change influence on solar cell increases
Solution Approach 1:
The patent replaces the traditional soldering mechanical system with a resin adhesive-based bonding system enhanced by mechanical interlocking (protrusions and recesses). This substitution reduces the thermal conductivity of the connection interface, thereby reducing the transmission of temperature changes to the solar cell while maintaining reliable electrical connection through the composite structure.
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 configuration maintains a reliable electrical connection and increases the mechanical robustness between the connection electrode and the wiring member, suppressing displacement of conductive particles and ensuring consistent energy output across temperature cycles.
Implementation Method 1
a resin adhesive is inserted between the wiring member and the connection electrode to bond the wiring member to the connection electrode
Implementation Method 2
since the sealant has a linear expansion coefficient larger than that of the wiring member, the wiring member receives stress from the sealant due to temperature change
Data Source
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AI summary
In a solar cell module 100, the wiring member 11 is connected onto the connection electrode 40 through a resin adhesive 12; and the connection electrode 40 includes a plurality of projections 40a which are in direct contact with the wiring member.