Solar Cell Soldering Inversion to Prevent Fracture
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Solution Overview
Problem
Traditional methods for producing crystalline silicon solar cell modules are inefficient, prone to fracturing due to repeated movement of thin solar cells, and result in power loss and complex manufacturing processes, requiring extensive equipment and area investments.
Innovation Solution
A method where all crystalline silicon solar cells and connecting strips are positioned on a bottom layer, allowing for simultaneous soldering and connection without moving the cells, using a non-contact soldering apparatus and flexible/rigid layers to reduce stress and simplify the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manual or automatic soldering methods are used to connect solar cells into cell strings, then the solar cells can be connected in series to form modules, but the cells must be moved multiple times which increases the risk of fracturing
Solution Approach 1:
Instead of moving the solar cells through a stationary soldering apparatus, the patent inverts the approach by keeping the solar cells stationary and moving the soldering apparatus (or the bottom layer with the cells) to perform soldering at multiple positions. This eliminates the need to repeatedly move and reposition the fragile solar cells, thereby reducing the risk of fracturing while maintaining the ability to connect all cells simultaneously.
Solution Approach 2:
The patent positions all solar cells and connecting strips on the bottom layer before the soldering process begins. This preliminary arrangement allows all soldering operations to be performed in place without subsequent movement of the cells, preventing hidden fractures that would occur during traditional multi-step moving and repositioning operations.
2Ease of manufacture
If the thickness of crystalline silicon solar cells is reduced to lower manufacturing cost, then production cost decreases, but the cells become more prone to fracturing during movement
Solution Approach 1:
The patent reverses the traditional approach where cells are moved through fixed equipment. By keeping the thin, fragile cells stationary and moving the soldering apparatus instead, the method enables the use of thinner, more cost-effective cells without compromising their structural integrity during the manufacturing process.
3Productivity
If automatic soldering machines are used to提高效率, then production speed increases, but the cells must be continuously moved which creates hidden fractures and power loss
Solution Approach 1:
The patent inverts the traditional automatic soldering approach by keeping all solar cells stationary on the bottom layer and moving the soldering apparatus to each cell position. This allows continuous automated soldering of all cells without the need to repeatedly move and reposition the cells, thereby maintaining high production efficiency while eliminating hidden fractures and power loss associated with cell movement.
Solution Approach 2:
All solar cells are pre-positioned on the bottom layer with connecting strips before the soldering process begins. This preliminary arrangement enables the automated soldering machine to efficiently process all cells in sequence without interruption or cell movement, achieving high productivity while preventing mechanical damage.
4Extent of automation
If traditional multi-step process is used to solder cells into strings and then connect them, then the process can be automated, but it requires extensive equipment and production area resulting in high investment
Solution Approach 1:
The patent merges the soldering and connecting operations into a single integrated process. All solar cells are positioned on one bottom layer and soldered simultaneously to form the complete module configuration, eliminating the need for separate string assembly and connection equipment. This consolidation reduces device complexity and production area requirements while maintaining full automation.
Solution Approach 2:
Instead of using multiple stationary workstations that require cells to be moved between them, the patent uses a single movable soldering apparatus that visits each cell position. This inversion of the traditional approach consolidates equipment into one unit rather than requiring multiple fixed stations, thereby reducing overall device complexity and space requirements.
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
Significantly reduces the risk of fracturing, simplifies the manufacturing process, lowers production costs, and minimizes power loss by minimizing cell movement and eliminating tensile forces during soldering and connecting.
Implementation Method 1
the crystalline silicon solar cells are soldered and connected
Data Source
AI summary
The present invention provides a method for producing a solar cell module; the present invention is characterized in that: in the process of soldering and connecting crystalline silicon solar cells, the crystalline silicon solar cells are kept still at positions on a bottom layer, and soldering and connecting of all crystalline silicon solar cells are implemented by moving a soldering apparatus or by moving the bottom layer; by means of the method for soldering and connecting crystalline silicon solar cells in the present invention, the process of soldering and connecting crystalline silicon solar cells is simplified and accelerated, and meanwhile, problems such as hidden fractures and power attenuation of the module occurring in the process of soldering and connecting solar cells are resolved.