Solar Cell Ribbon With Segmented Insulating And Solder Layers
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Solution Overview
Problem
Existing solar cell panel ribbons do not adequately improve the properties of solar cell panels, such as electrical connectivity and aesthetic appearance, due to limitations in their structural design and manufacturing processes.
Innovation Solution
A ribbon for solar cell panels is designed with an insulating layer on one side and a solder layer on the opposite side, which is formed by immersing the ribbon body in solder material, enhancing electrical connections and hiding the ribbon from view to improve aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ribbon structure is used for connecting solar cells, then the manufacturing process is simple, but the electrical connectivity and aesthetic appearance of the solar cell panel are insufficient
Solution Approach 1:
The ribbon is divided into distinct functional zones: an insulating layer covering portion of the longitudinal surface and a solder layer covering the remaining portion. This segmentation allows different regions to perform different functions - the insulating layer prevents unwanted electrical connections while the solder layer ensures reliable electrical connectivity, thereby improving overall reliability without requiring multiple separate components
Solution Approach 2:
The ribbon employs a composite structure combining insulating material and solder material in a single integrated component. The insulating layer and solder layer are formed on different portions of the ribbon body, creating a composite structure that simultaneously provides electrical insulation where needed and electrical conductivity where required, improving electrical connectivity while maintaining structural simplicity
2Ease of manufacture
If the ribbon is fully exposed on the solar cell panel surface, then the manufacturing process is simple, but the aesthetic appearance is poor
Solution Approach 1:
The insulating layer is applied selectively to specific portions of the ribbon's longitudinal surface - specifically covering portions that would be visible on the front surface of the solar cell panel. This local application of insulating material provides aesthetic improvement by concealing the metallic ribbon appearance in visible areas, while the solder layer remains available on other portions to ensure proper electrical connections during manufacturing
3Shape
If the insulating layer is applied to the entire ribbon surface, then aesthetic appearance is improved, but electrical connectivity is compromised
Solution Approach 1:
The ribbon surface is segmented into distinct functional zones: an insulating layer covering portion of the longitudinal surface and a solder layer covering the remaining portion. This segmentation allows different regions to perform different functions - the insulating layer prevents unwanted electrical connections while the solder layer ensures reliable electrical connectivity, thereby improving overall reliability without requiring multiple separate components
Solution Approach 2:
The insulating layer is applied selectively to specific portions of the ribbon's longitudinal surface, specifically covering portions that would be visible on the front surface of the solar cell panel. This local application provides aesthetic improvement while the solder layer remains available on other portions to ensure proper electrical connections
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 solution improves the electrical connectivity and appearance of solar cell panels by ensuring reliable soldering and concealing the ribbons, thereby enhancing the panel's efficiency and visual appeal.
Implementation Method 1
forming a solder layer throughout a remaining portion excluding the insulating layer over the longitudinal surface of the ribbon body, the solder layer being disposed throughout at least a back surface opposite to the front surface by immersing the ribbon body, having the insulating layer formed thereon, in a solder material
Data Source
Figure 1
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Figure 4
AI summary
Disclosed is a ribbon (142, 145) for a solar cell panel including a ribbon body (1420, 1450), an insulating layer (1422, 1452) disposed on at least one side over a longitudinal surface of at least the ribbon body, and a solder layer (1424, 1454) disposed throughout a portion excluding the insulating layer over the longitudinal surface of the ribbon body, the solder layer being disposed throughout at least a remaining side opposite to the one side.