Solar Cell Panel Conductive Adhesive Tabbing

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Solution Overview

Problem

The existing solar cell panel tabbing process faces challenges with alignment errors between solar cells and interconnectors, requiring costly and high-temperature soldering, which can damage the substrate and cause bowing phenomena.

Innovation Solution

A solar cell panel design incorporating a conductive adhesive film with resin and conductive particles, along with alignment marks on the substrate, allows for direct electrical connection of front electrodes to interconnectors at low temperatures, reducing the need for a front electrode current collector and minimizing alignment errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-temperature soldering is used to connect front electrodes to interconnectors, then electrical connection reliability is improved, but substrate damage and bowing phenomena occur

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidsubstrate damage and bowing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the temperature parameter from high-temperature soldering (typically above 220°C) to low-temperature conductive adhesive bonding (below 180°C). This parameter change maintains electrical connection reliability while avoiding substrate damage and bowing phenomena that occur with high-temperature processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical soldering process with a conductive adhesive bonding process. The conductive adhesive film with resin and conductive particles provides both mechanical bonding and electrical conductivity, substituting the traditional soldering mechanism while reducing thermal stress on the substrate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If alignment marks are not used, then manufacturing process is simpler, but alignment errors between solar cells and interconnectors increase

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent implements alignment marks on the substrate before the tabbing process. These pre-positioned marks guide the placement of interconnectors and conductive adhesive, ensuring accurate alignment between solar cells and interconnectors while maintaining a relatively simple manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a front electrode current collector is used, then electrical connection is more reliable, but process complexity and cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of the front electrode current collector with the interconnector and conductive adhesive film. The interconnector directly contacts the front electrodes through the conductive adhesive, eliminating the need for a separate current collector layer while maintaining reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and removes the front electrode current collector from the solar cell structure. By using conductive adhesive to directly bond interconnectors to front electrodes, the unnecessary current collector layer is eliminated, reducing structural complexity and manufacturing cost.

Inventive Principle:

Principle #2Taking out (Extraction)

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 minimizes alignment errors, reduces process and cost requirements, and prevents substrate damage by enabling the tabbing process at temperatures below 180°C, thereby improving efficiency and durability.

Implementation Method 1

a conductive adhesive film including a resin and a plurality of conductive particles dispersed in the resin, the conductive adhesive film being positioned between the plurality of front electrodes and the interconnector in the second direction to electrically connect the plurality of front electrodes to the interconnector

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

Solar power generation to convert light energy into electric energy using a photoelectric conversion effect has been widely used as a method for obtaining eco-friendly energy

Methodology Applied

Scientific EffectPhotoelectric effect: Photoelectric Effect

Data Source

PatentUS9147787B2Solar cell panel

Publication Date: 2015.09.29 TRINA SOLAR CO LTD

AI summary

A solar cell panel is discussed. The solar cell panel includes a plurality of solar cells each including a substrate, an emitter layer positioned at a light receiving surface of the substrate, and a plurality of front electrodes that are electrically connected to the emitter layer and extend parallel to one another in a first direction, an interconnector that electrically connects adjacent ones of the solar cells to each other and is positioned in a second direction crossing the front electrodes, a conductive adhesive film that is positioned between the front electrodes and the interconnector in the second direction and electrically connects the front electrodes to the interconnector, and an alignment mark indicating a bonding location of the conductive adhesive film, and positioned on the substrate.