Solar Cell Module Interconnector Fixation via Pressure-Sensitive Adhesive
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Solution Overview
Problem
The existing solar cell module manufacturing processes are complex and require multiple steps, including a separate tabbing process for electrical connections, which can lead to alignment issues and increased manufacturing costs due to the need for additional adhesives and materials.
Innovation Solution
A solar cell module design that uses a conductive adhesive with a pressure-sensitive insulating adhesive tape to temporarily fix interconnectors to electrode parts at room temperature, eliminating the need for a separate curing process and simplifying the manufacturing process by integrating the tabbing step into the lamination process, while reducing material usage and preventing substrate bowing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate tabbing process is used to electrically connect interconnectors to solar cells, then electrical connection reliability is improved, but the number of manufacturing processes increases and manufacturing complexity worsens
Solution Approach 1:
The patent combines the tabbing process with the lamination process by applying conductive adhesive during lamination. The interconnectors are temporarily fixed with insulating adhesive portion, then conductive adhesive is applied in the same process sequence, eliminating the need for a separate tabbing step while maintaining electrical connection reliability.
Solution Approach 2:
The insulating adhesive portion is applied beforehand to temporarily fix the interconnectors to the solar cells before the conductive adhesive is applied. This preliminary fixation ensures proper positioning and prevents alignment issues during the subsequent lamination and tabbing processes.
2Reliability
If multiple adhesives and materials are used for tabbing and insulation, then connection reliability is improved, but material usage increases and manufacturing cost worsens
Solution Approach 1:
The patent extracts and separates the insulation function from the electrical connection function. The insulating adhesive portion is applied only where insulation is needed (between interconnectors and solar cell surfaces), while the conductive adhesive is applied only where electrical connection is needed (between interconnectors and electrode parts). This reduces overall material usage compared to applying multiple adhesives across entire surfaces.
Solution Approach 2:
The patent applies adhesives locally rather than uniformly across entire surfaces. The insulating adhesive portion is positioned specifically between the interconnector and the solar cell surface, while the conductive adhesive is applied specifically at the contact points with electrode parts. This localized application reduces material consumption while maintaining connection reliability.
3Strength
If a curing process is performed for adhesive bonding, then bond strength is improved, but manufacturing time and process complexity worsen
Solution Approach 1:
The patent merges the adhesive bonding process with the lamination process. Both the insulating adhesive portion and the conductive adhesive are applied and cured simultaneously during the lamination step, eliminating the need for a separate curing process and reducing manufacturing time while maintaining bond strength.
4Manufacturing precision
If interconnectors are fixed with adhesive before lamination, then alignment precision is improved, but the risk of substrate bowing increases
Solution Approach 1:
The insulating adhesive portion acts as an intermediary that temporarily fixes the interconnectors without creating strong bonds that would cause substrate bowing. It provides sufficient positioning stability during lamination but allows the substrate to remain flat, preventing the harmful bowing effect while maintaining alignment precision.
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 approach reduces the number of manufacturing processes, prevents alignment issues during lamination, minimizes material usage, and lowers production costs by allowing for local fixation of interconnectors with a smaller adhesive area, thereby enhancing the efficiency and cost-effectiveness of solar cell module production.
Implementation Method 1
a conductive adhesive configured to electrically connect each of the plurality of interconnectors to the corresponding electrode part
Implementation Method 2
at least one insulating adhesive portion configured to temporarily fix the plurality of interconnectors to the corresponding electrode part, wherein the at least one insulating adhesive portion includes an adhesive having adhesiveness to attach the interconnector to the corresponding electrode part at the room temperature
Data Source
Figure 1
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Figure 4
AI summary
A solar cell module includes a plurality of solar cells each including a semiconductor substrate and first and second electrode parts each having a different polarity, a plurality of interconnectors for electrically connecting the plurality of solar cells, a conductive adhesive for electrically connecting each of the plurality of interconnectors to the corresponding electrode part of each of the plurality of solar cells, and at least one insulating adhesive portion for temporarily fixing the plurality of interconnectors to the corresponding electrode part. The at least one insulating adhesive portion includes an adhesive having adhesiveness to attach the interconnector to the corresponding electrode part at the room temperature.