Solar Cell Interconnector With Insulating Member
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Solution Overview
Problem
Current solar cell module technologies face challenges in efficiently connecting solar cells with minimal thermal expansion stress and maximizing optical gain, while maintaining manufacturing simplicity and cost-effectiveness.
Innovation Solution
The solar cell module design incorporates a first and second solar cell with auxiliary electrodes and an insulating member, where the interconnector connects the cells without overlapping the semiconductor substrate, allowing for thermal expansion management and enhanced optical gain through a non-uniform interconnector surface and zigzag shape, facilitating easy connection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the interconnector overlaps the semiconductor substrate to connect solar cells, then the electrical connection is simplified, but thermal expansion stress increases and optical gain is reduced
Solution Approach 1:
The patent introduces an insulating member as an intermediary component between the interconnector and the semiconductor substrate. This insulating member allows the interconnector to connect adjacent solar cells without directly overlapping the substrate, thereby reducing thermal expansion stress while maintaining electrical connection functionality through the insulating member's dielectric properties.
Solution Approach 2:
The patent transitions from a planar connection approach to a three-dimensional structure by stacking components vertically. The interconnector is positioned in a different vertical layer than the semiconductor substrate, connected through the insulating member, which allows electrical connection without direct overlap and minimizes thermal stress on the substrate.
2Manufacturing precision
If the interconnector has a flat surface to simplify manufacturing, then manufacturing precision is improved, but optical gain is reduced due to less light reflection
Solution Approach 1:
The patent applies curved or zigzag surface structures to the interconnector instead of a flat surface. This curvature increases light reflection and scattering, thereby enhancing optical gain and reducing energy loss while maintaining manufacturability through standard deposition techniques.
Solution Approach 2:
The patent implements different surface properties in different regions of the interconnector. The top surface features curved or zigzag structures optimized for light reflection, while the bottom surface maintains a flat configuration for precise alignment and connection with the insulating member, combining optical performance with manufacturing precision.
3Strength
If the solar cells are connected using metal interconnectors with metal bonding, then electrical connection strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces an insulating member as an intermediary that simplifies the manufacturing process. This insulating member pre-formed with conductive patterns serves as a ready-to-connect component, eliminating complex metal bonding steps while maintaining strong electrical connections through the conductive pathways already integrated into the insulating member.
Solution Approach 2:
The patent combines the insulating and conducting functions into a single integrated component (the insulating member with conductive patterns). This merging eliminates the need for separate insulating layers and metal interconnectors, reducing manufacturing steps and costs while maintaining electrical connection strength.
Data Source
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AI summary
A solar cell module includes first and second solar cells and an interconnector (IC) for electrically connecting the first and second solar cells. The first solar cell (Cell-a) and the second solar cell (Cell-b) each include a plurality of first electrodes (C141) formed on a back surface of a semiconductor substrate, a plurality of second electrodes (C142) formed on the back surface of the semiconductor substrate, a first auxiliary electrode (P141) connected to the plurality of first electrodes, a second auxiliary electrode (P142) connected to the plurality of second electrodes, and an insulating member (200) positioned on back surfaces of the first auxiliary electrode and the second auxiliary electrode. Each of the first solar cell and the second solar cell is formed as an individual integrated type element by connecting one semiconductor substrate and one insulating member.