Solar Cell Module Positioning Unit for Conductor Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar cell modules face displacement and interconnector damage due to thermal expansion and contraction during the lamination process, particularly when using resin materials like polycarbonate for weight reduction, which affects the reliable positioning of conductors.
Innovation Solution
A solar cell module design featuring a first and second cover with a positioning unit, where the positioning unit is integrated with a colored portion on the first cover, allowing for reliable conductor positioning between the covers, preventing displacement during thermal changes, and maintaining an aesthetically pleasing appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If resin materials like polycarbonate are used for the front plate to reduce weight, then the weight of the solar cell module is reduced, but thermal expansion and contraction during lamination causes displacement and interconnector damage
Solution Approach 1:
The positioning unit is integrated into the front plate before the lamination process, establishing predetermined positions for conductors and solar cells. This preliminary positioning structure prevents displacement during thermal expansion and contraction that occurs during lamination, thereby maintaining reliability while using lightweight resin materials.
2Ease of manufacture
If conventional lamination process is used without positioning units, then the manufacturing process is simple, but conductors and solar cells experience displacement and interconnector damage
Solution Approach 1:
The positioning unit is integrated directly into the front plate structure, combining the functions of the front plate and positioning mechanism into a single component. This integration maintains manufacturing simplicity while providing precise positioning for conductors and solar cells during the lamination process.
3Reliability
If positioning units are added to the front plate or back plate, then conductor positioning reliability is improved, but the device complexity increases
Solution Approach 1:
The positioning unit is formed as an integral part of the front plate or back plate through molding or forming processes, rather than being a separate component. This integration maintains structural simplicity while providing reliable positioning functionality, avoiding the need for additional separate positioning devices.
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 positioning unit ensures conductors are reliably positioned, preventing displacement and damage from thermal expansion and contraction, enhancing the module's stability and manufacturing efficiency while maintaining an attractive external appearance.
Implementation Method 1
heating and pressurization is conducted by a lamination device to cure the sealing material
Implementation Method 2
heating and pressurization is conducted by a lamination device to cure the sealing material
Implementation Method 3
thermal expansion and contraction of a front plate and a back plate
Implementation Method 4
thermal expansion and contraction of a front plate and a back plate
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A solar cell module (110) includes: a first cover (111) in the form of an at least partially transparent plate; a second cover (112) disposed opposite the first cover (111); at least one solar cell (113) disposed between the first cover (111) and the second cover (112); a sealing material (114) which fills a space between the first cover (111) and the second cover (112) to join them together to thus seal the solar cell (113); and a terminal (221, 231) as conductors electrically connected to the solar cell (113) and enclosed by the sealing material (114) between the first cover (111) and the second cover (112), at least one of the first cover (111) and the second cover (112) having a boss (121a) as a positioning unit to position the terminal (221, 231).