Solar Cell Module Stepped Substrate Design
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Solution Overview
Problem
Existing solar cell modules face challenges in assembly due to the rigidity and bending issues of thin substrates, leading to poor productivity and misalignment of solar cell pieces in electronic devices like wristwatches.
Innovation Solution
A solar cell module design featuring a substrate with a mutually fittable shape between pieces, where the length of the fittable shape is longer than the straight-line distance between ends, preventing folding and misalignment, and allowing for easier assembly even when the substrate is bent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the substrate is made thinner to achieve lighter and thinner electronic devices, then the device weight and thickness are reduced, but the substrate rigidity decreases causing bending and assembly difficulties
Solution Approach 1:
The solar cell panel is divided into multiple pieces that are arranged in a stepped configuration on the substrate. This segmentation allows the substrate to be thinner while maintaining overall structural rigidity through the distributed piece arrangement, preventing bending issues that would occur with a single large piece on a thin substrate.
2Adaptability or versatility
If the solar cell panel is cut into multiple pieces and assembled to the electronic device, then the device can accommodate the solar cell structure, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
Multiple solar cell pieces are arranged in a stepped configuration and connected to form an integrated solar cell panel structure. This merging approach allows the multiple pieces to be treated as a single assembly unit, simplifying the assembly process to one operation rather than multiple separate assembly steps, thereby improving productivity while maintaining adaptability to the electronic device.
3Weight of moving object
If the substrate is thin and bent, then lighter devices can be achieved, but the solar cell pieces become misaligned and assembly becomes difficult
Solution Approach 1:
The solar cell pieces are arranged in a stepped configuration where each successive piece is positioned at a different height level. This stepped (curved) arrangement compensates for substrate bending by creating a three-dimensional structure that maintains proper piece alignment even when the thin substrate bends, thereby preserving manufacturing precision while enabling lightweight construction.
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 ensures a flat assembly of solar cell modules, enhancing productivity and efficiency in power generation by maintaining the solar cell panel's flat state and optimizing power generation area, while allowing for easier manufacturing and installation in devices.
Implementation Method 1
a solar timepiece including a solar cell has been widely used... the solar timepiece includes a support substrate and the solar cell having multiple solar cell elements formed on a surface of the support substrate
Data Source
AI summary
A solar cell module includes a solar cell panel configured to have multiple pieces and a substrate that connects the multiple pieces to each other. The multiple pieces include a first piece and a second piece adjacent to the first piece. Opposing sides of the first piece and the second piece respectively have a mutually fittable shape. A length of the mutually fittable shape is longer than a distance of a straight line which connects both ends of the mutually fittable shape.