Solar Cell Interconnect Structure With Discontinuous Contact Layout
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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 conventional soldering pads with metallized paste are used for interconnection, then reliable electrical connection is achieved, but light-receiving area is reduced and manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the conventional soldering pad structure from the solar cell surface. Instead of using metallized paste pads, the invention uses the solar cell's existing busbar structure directly as the connection point, removing the unnecessary intermediate soldering pad layer that blocks light and increases cost.
Solution Approach 2:
The busbar structure is given multiple functions: it serves both as the current collection conductor and as the direct soldering surface for PV ribbons. This eliminates the need for separate soldering pads, reducing material usage and light blocking while maintaining electrical connection reliability.
2Reliability
If PV ribbon protective films are used during assembly, then hot spot damage is prevented, but manufacturing cost increases
Solution Approach 1:
The patent replaces the expensive PV ribbon protective film with a low-cost alternative: the encapsulant material itself serves as the protective barrier. The encapsulant, which is already required for module encapsulation, provides hot spot protection without needing an additional specialized protective film layer.
3Reliability
If PV ribbon protective films are used, then hot spot effect is avoided, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the hot spot protection function with the existing encapsulation process. The encapsulant material simultaneously provides mechanical protection, environmental sealing, and hot spot protection, eliminating the need for separate protective film application and removal steps in the manufacturing process.
4Strength
If conventional busbar with metallized paste is used, then sufficient tension is provided, but manufacturing cost increases
Solution Approach 1:
The patent applies metallized paste only where absolutely necessary - directly at the soldering interface between the PV ribbon and busbar - rather than coating the entire busbar surface. This localized application provides sufficient mechanical tension and electrical connection while dramatically reducing paste consumption and cost.
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 reduces manufacturing costs, avoids hot spots, and simplifies the process by ensuring a larger light-receiving area and stable electrical connections.
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
Data Source
Figure 1
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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.