Solar Cell Panel Narrow Wire Interconnection
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Solution Overview
Problem
Solar cell panels face limitations in output and reliability due to shading loss and poor attachment strength caused by wide ribbons used for connecting solar cells, which also increase the risk of ribbon separation and damage.
Innovation Solution
A solar cell panel design featuring narrower wires with a smaller width, typically between 250µm to 500µm, that interconnect solar cells with a specific cross-sectional shape and structure, including a core layer and solder layer, to enhance electrical connection and attachment force while minimizing shading loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wide ribbons are used to connect solar cells, then attachment strength is improved, but shading loss increases
Solution Approach 1:
The connection structure is segmented into multiple thin wire portions instead of using a single wide ribbon. Each wire portion has a width of 250-500µm, and multiple wires are arranged to provide both electrical connection and mechanical support, reducing shading loss while maintaining attachment strength through distributed contact points.
Solution Approach 2:
The width parameter of the connection element is changed from large (ribbon width approximately 1.5mm) to small (wire width 250-500µm). This parameter change reduces the shading area while the number of wires is optimized to maintain sufficient electrical conductivity and mechanical attachment strength.
2Device complexity
If wide ribbons are used to connect solar cells, then electrical connection is simplified, but shading loss increases
Solution Approach 1:
The single wide ribbon connection is segmented into multiple thin wire connections. While this increases the number of components, each wire is simpler in structure with a uniform cross-section, and the overall system achieves better optical performance by distributing the electrical pathways across multiple thin conductors.
3Reliability
If multiple ribbons are provided on solar cells, then electrical connection is improved, but shading loss increases
Solution Approach 1:
The electrical connection is achieved through multiple segmented wire portions rather than fewer wide ribbons. Each wire provides an independent electrical pathway, and the collective arrangement of multiple thin wires maintains reliable electrical connection while minimizing the total shaded area on the solar cell surface.
Solution Approach 2:
The connection element dimensions are changed from wide ribbons (1.5mm) to thin wires (250-500µm width). This parameter change allows multiple wires to be arranged on the solar cell surface, providing redundant electrical pathways and improved reliability while the thin profile of each wire minimizes shading loss.
4Ease of manufacture
If wide ribbons are used to connect solar cells, then manufacturing is simplified, but attachment strength deteriorates
Solution Approach 1:
The connection structure is manufactured using multiple thin wire portions that can be individually processed and attached. This segmentation allows for better control of each wire's attachment quality, ensuring strong mechanical bonding at each contact point while the cumulative effect of multiple wires provides overall structural support.
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
The design increases the output and reliability of solar cell panels by reducing shading loss, improving attachment force, and enhancing electrical properties, while also reducing material costs and stress on the solar cells.
Implementation Method 1
a solder layer which is coated on the outer surface of the core layer
Data Source
Figure 1
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Figure 4
AI summary
Disclosed is a solar cell panel including a plurality of solar cells each including a semiconductor substrate and an electrode formed on the semiconductor substrate, and a wire for interconnecting the solar cells. The electrode includes a bus-bar line having a pad portion for attachment of the wire. The wire includes a first wire portion connected to the pad portion, and a second wire portion located on a portion excluding the pad portion. The first wire portion has a thickness greater than a thickness of the second wire portion.