Solar Cell Interconnector Layout for Thermal Stress Relief
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Solution Overview
Problem
Existing solar cell module technologies face challenges in efficiently connecting solar cells with varying electrode configurations, leading to thermal expansion stress and alignment issues during the connection process.
Innovation Solution
A solar cell module design featuring interconnectors with distinct connection areas, shapes, and positions for each solar cell, allowing for differential overlap and connection configurations between conductive lines, which reduces thermal expansion stress and simplifies the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If symmetric connection areas are used for both conductive lines, then manufacturing simplicity is maintained, but thermal expansion stress increases and alignment precision deteriorates
Solution Approach 1:
The patent applies asymmetry by configuring the first connection area of the interconnector to have a different area from the second connection area. This asymmetric design allows differential overlap with the first and second conductive lines, enabling precise alignment compensation for each line independently, thereby improving alignment precision while managing thermal expansion stress.
Solution Approach 2:
The patent implements local quality by making each connection area have distinct properties tailored to its specific conductive line. The first connection area is optimized for the first conductive line with specific overlap characteristics, while the second connection area is optimized for the second conductive line, allowing localized adjustment of connection quality and alignment precision.
2Reliability
If precise alignment of connection areas is required, then connection reliability improves, but the connection process complexity and difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the interconnector with distinct first and second connection areas having different areas before the connection process. This pre-designed asymmetric structure enables automatic alignment compensation during assembly, achieving reliable connections without requiring complex real-time alignment procedures, thereby improving ease of manufacture.
Solution Approach 2:
The patent implements parameter changes by varying the area parameter of the connection areas. The first connection area has a different area than the second connection area, allowing optimization of each connection for its specific conductive line. This parameter variation enables reliable connections while simplifying the manufacturing process by eliminating the need for precise manual alignment.
3Adaptability or versatility
If uniform overlap areas are used for both solar cells, then manufacturing consistency is maintained, but adaptability to varying solar cell configurations decreases
Solution Approach 1:
The patent applies universality by designing the interconnector with a multi-functional connection structure that can adapt to different solar cell configurations. The asymmetric connection areas enable the same interconnector design to work with varying conductive line arrangements on different solar cells, providing configuration adaptability while maintaining manufacturing consistency through a standardized yet flexible design.
Solution Approach 2:
The patent implements dynamics by creating a connection structure that can dynamically adapt to different overlap requirements. The distinct first and second connection areas allow the interconnector to flexibly accommodate varying solar cell configurations, enabling the same component to maintain consistent manufacturing quality across different application scenarios through inherent design flexibility.
Data Source
AI summary
A solar cell module includes first and second solar cells each including a plurality of first and second electrodes formed on a back surface of a semiconductor substrate, a first conductive line connected to the first electrodes, and a second conductive line connected to the second electrodes, and an interconnector connecting the first conductive line of the first solar cell to the second conductive line of the second solar cell. At least one of an area of an overlap portion, an area of a connection portion, a connection position, and a connection shape between the interconnector and the first conductive line of the first solar cell is different from at least one of an area of an overlap portion, an area of a connection portion, a connection position, and a connection shape between the interconnector and the second conductive line of the second solar cell.