Conductive Interconnect Geometry for Flip-Free Solar Cell Assembly
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Solution Overview
Problem
The assembly of solar cell assemblies is complex and prone to damage due to the need for multiple components and steps, including welding different types of interconnects and flipping the assembly, which complicates the process and increases the risk of disconnection or damage.
Innovation Solution
A conductive interconnect system with a first end and a second end aligned on an axis, configured to interface with solar cell edges, allowing for easy connection and disconnection while maintaining electrical conductivity, and a center portion that can partially deform to accommodate mechanical and thermal changes, enabling efficient and adaptive assembly without flipping the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple types of interconnects and welding steps are used to connect solar cells, then the electrical connection between solar cells is achieved, but the assembly process becomes complex and the likelihood of damage increases
Solution Approach 1:
The conductive interconnect is designed as a universal component that performs multiple functions: it provides electrical conductivity between solar cells, offers mechanical support for positioning, and enables simplified assembly through its specific geometric configuration with concave openings. This single multi-functional component replaces what would otherwise require multiple separate components and complex welding procedures.
Solution Approach 2:
The invention merges the electrical conduction function, mechanical positioning function, and structural support function into a single integrated conductive interconnect component. The center portion and concave openings are combined with the conductive ends to create one unified element that accomplishes multiple objectives simultaneously, reducing assembly complexity.
2Ease of manufacture
If traditional welding and flipping steps are used to assemble solar cells, then the solar cell assembly is formed, but the assembly time increases and the risk of disconnection or damage increases
Solution Approach 1:
The conductive interconnect is pre-configured with its specific geometric shape including concave openings that are designed to interface with solar cell edges before assembly occurs. This preliminary configuration allows the interconnect to be positioned and connected without requiring complex positioning steps or flipping operations during the assembly process, thereby reducing assembly time and improving ease of manufacture.
3Ease of operation
If the assembly is flipped after welding interconnects, then the assembly can be completed, but the likelihood of damage to the assembly increases
Solution Approach 1:
Instead of completing assembly and then flipping the entire assembly as in traditional methods, the conductive interconnect design allows the opposite approach: the interconnect's geometric configuration with concave openings enables it to be positioned and secured in its final orientation during assembly, eliminating the need for post-assembly flipping and thereby protecting the assembled structure from damage.
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 simplifies the assembly process, reduces the likelihood of damage, and allows for quick, robust, and adaptive solar cell assemblies by using identical conductive interconnects for all connections, ensuring continuous electrical conductivity even under mechanical or thermal changes.
Implementation Method 1
The center portion connecting the first end to the second end and configured to conduct electricity between the first end and the second end
Data Source
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AI summary
A system of interconnected solar cells is described. The system includes a first solar cell. The system includes a second solar cell adjacent to the first solar cell. The system includes a conductive interconnect configured to conduct electricity between a first terminal of the first solar cell and a second terminal of the second solar cell. The conductive interconnect includes a first end aligned on an axis and configured to conduct electricity at a first terminal on the first solar cell. The conductive interconnect includes a second end aligned on the axis and configured to conduct electricity at a second terminal on the second solar cell. The conductive interconnect includes a center portion connecting the first end to the second end and configured to conduct electricity between the first end and the second end.