Solar Cell Panel Segmented Leads Reduce Shading Loss
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Solution Overview
Problem
Solar cell panels face limitations in output power due to shading loss and high costs associated with conductive adhesive films used for interconnecting solar cells, as well as complexity in the attachment process, particularly when using wide ribbons for connections.
Innovation Solution
A solar cell panel design featuring a plurality of solar cells connected by leads with a diameter or width of 100 to 500µm, arranged in a circular cross-section, which reduces carrier movement paths and minimizes light loss through diffuse reflection, and are attached using a solder layer with metal particles and cross-linking resin to enhance reliability and simplify the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wide ribbons are used to connect solar cells, then the connection strength is improved, but shading loss increases and output power is reduced
Solution Approach 1:
The patent divides the connection structure into multiple thin leads (6 or more per surface) instead of using a single wide ribbon. Each lead has a width of 100-500μm, which is much narrower than conventional ribbons. This segmentation allows carriers to reach multiple collection points, reducing the movement path length while minimizing the shading area caused by connection elements.
2Loss of energy
If the number of ribbons is reduced to minimize shading loss, then shading loss is reduced, but carrier movement path becomes longer and output power enhancement is limited
Solution Approach 1:
The patent implements a segmented connection architecture with 6 or more thin leads distributed across each solar cell surface. This segmentation creates multiple short carrier collection paths, allowing carriers to reach the nearest lead quickly without traveling long distances. The thin leads minimize shading loss while the increased number of leads provides multiple collection points, thereby enhancing output power.
3Ease of manufacture
If conductive adhesive films are used to attach ribbons to solar cell electrodes, then the attachment process is simplified, but material cost increases and process complexity increases
Solution Approach 1:
The patent replaces expensive conductive adhesive films with a solder layer connection method. The solder layer provides reliable electrical and mechanical connection between the thin leads and solar cell electrodes without requiring additional adhesive materials. This substitution significantly reduces material costs while maintaining connection reliability.
4Loss of energy
If thin leads with small width are used to reduce shading loss, then shading loss is minimized, but alignment precision requirements increase and connection reliability may decrease
Solution Approach 1:
The patent merges multiple thin leads (6 or more per surface) into a coordinated network that collectively provides robust carrier collection. While each individual lead is thin (100-500μm) to minimize shading, the combined effect of multiple leads distributed across the solar cell surface ensures that alignment tolerances are more forgiving and connection reliability is enhanced through redundancy.
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 improves solar cell panel output by reducing carrier movement paths, minimizing light loss, and stabilizing electrical connections, while reducing material costs and simplifying the attachment process, thereby enhancing the panel's efficiency and reliability.
Implementation Method 1
The plurality of leads are connected to the plurality of first bus bars of the first solar cell and the plurality of second bus bars of the second solar cell by a solder layer, respectively
Data Source
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AI summary
A solar cell panel includes a first solar cell and a second solar cell; and a plurality of leads connecting the first solar cell and the second solar cell. Each of the first solar cell and the second solar cell includes: a first electrode including a plurality of finger lines in a first direction and a plurality of first bus bars in a second direction crossing the first direction; and a second electrode including a plurality of second bus bars in the second direction. The plurality of leads have a diameter or width of 100 to 500㎛, and include 6 or more leads arranged at one surface side of the first or second solar cell. The plurality of leads are connected to the plurality of first bus bars of the first solar cell and the plurality of second bus bars of the second solar cell by a solder layer, respectively.