Solar Cell Module Series Connection via Conductive Adhesive
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Solution Overview
Problem
Existing solar cell modules face challenges in efficiently connecting multiple solar cells in series while maintaining low manufacturing costs and minimizing defects such as short circuits, which can lead to increased defect rates and reduced efficiency.
Innovation Solution
The solar cell module design incorporates a configuration of conductive lines and insulating layers with specific thickness and width ratios, along with conductive adhesives and encapsulants, to ensure reliable electrical connections and prevent short circuits, using materials like copper, aluminum, and ethylene vinyl acetate for enhanced durability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive lines and insulating layers are used to connect solar cells in series, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent introduces conductive adhesives as intermediary materials between conductive lines and electrode regions, and insulating layers as mediators between conductive lines and opposite polarity electrodes. These intermediary elements simplify the manufacturing process by providing standardized connection interfaces while ensuring reliable electrical connections and preventing short circuits.
Solution Approach 2:
The patent divides the connection structure into distinct functional segments: conductive lines for electrical connection, conductive adhesives for bonding, and insulating layers for isolation. This segmentation allows each component to be optimized independently and simplifies the overall manufacturing process by enabling modular assembly.
2Reliability
If conductive adhesives with larger thickness are used, then electrical connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies that conductive adhesive thickness should be larger than insulating layer thickness, creating a parameter relationship that ensures reliable electrical connection while providing manufacturing tolerance. The greater thickness of conductive adhesive compensates for variations in application thickness, maintaining connection reliability even with moderate precision control.
3Device complexity
If insulating layers are positioned close to conductive lines, then device complexity is reduced, but short circuit risk increases
Solution Approach 1:
The patent positions insulating layers as intermediary elements between conductive lines and opposite polarity electrodes, creating physical separation that prevents short circuits. This intermediary structure maintains simplicity by using a single insulating layer component while effectively eliminating the harmful short circuit risk through proper spatial arrangement.
4Power
If multiple solar cells are connected in series, then power output is improved, but defect rate increases
Solution Approach 1:
The patent divides the solar cell array into multiple series-connected cells, each with standardized connection interfaces using conductive adhesives and insulating layers. This segmentation allows for modular assembly where consistent connection structures reduce variability-induced defects while achieving higher overall power output through series connection.
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 configuration effectively reduces the defect rate and maintains low line resistance, ensuring efficient electrical connections and improved durability of the solar cell module, while allowing for easy replacement of faulty cells and enhanced light absorption through optimized electrode placement.
Implementation Method 1
a plurality of conductive adhesives each formed at a crossing area between the plurality of first conductive lines and the plurality of first electrodes, and between the plurality of second conductive lines and the plurality of second electrodes
Implementation Method 2
a plurality of insulating layers formed at a crossing area between the plurality of first conductive lines and the plurality of second electrodes, and between the plurality of second conductive lines and the plurality of first electrodes
Implementation Method 3
solar cells for generating electric energy from solar energy
Data Source
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AI summary
A solar cell module includes a plurality of solar cells, each solar cell including a semiconductor substrate, an emitter region, a back surface field region a first electrode connected to the emitter region, a second electrode connected to the back surface field region, and a conductive line connected to one electrode of the first and second electrodes using a conductive adhesive and insulated from the other electrode of the first and second electrodes through an insulating layer, the conductive line being used to connect a plurality of solar cells in series. A thickness of the conductive adhesive between the one electrode and the conductive line is greater than a thickness of the insulating layer between the other electrode and the conductive line.