Solar Cell String Repair via Thermal Separation and Segmented Wiring
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Solution Overview
Problem
Solar cell modules face issues with interconnector separation due to temperature changes and defects in rear contact solar cells, leading to increased failure rates and reduced long-term reliability, especially when replacing defective cells is difficult.
Innovation Solution
A method and structure for manufacturing solar cell modules that allows for easy replacement of defective cells by thermally processing the connection areas between conductive wirings and intercell connectors, using a repair device to separate and replace target solar cells, and reinforcing the wiring portion with a fixing member to enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If interconnectors are used to connect multiple solar cells in a module, then the solar cells can be electrically connected and form functional modules, but the interconnectors separate due to repeated thermal expansion and contraction, leading to module failure
Solution Approach 1:
The patent divides the connection structure into separate functional elements: solar cells, intercell connectors, and conductive wirings. The conductive wirings are separately connected to multiple solar cells and then joined to the intercell connector, creating modular connection points that can accommodate thermal stress independently, preventing catastrophic failure of the entire connection system.
Solution Approach 2:
The patent introduces conductive wirings as intermediary elements between the solar cells and the intercell connector. These wirings act as flexible mediators that can absorb thermal expansion and contraction stresses, preventing direct stress transmission between the rigid solar cells and intercell connector, thereby maintaining connection integrity under temperature variations.
2Reliability
If rear contact solar cells are used with overlapped interconnectors, then the electrical connection is achieved, but the adhesion weakness causes interconnector separation and increases inferiority rate
Solution Approach 1:
The patent segments the connection system into replaceable modules where defective solar cells can be individually identified and replaced. The conductive wirings and intercell connectors are designed as separate components that can be independently manipulated, allowing defective cells to be replaced without damaging the entire module's electrical connection system.
Solution Approach 2:
The patent performs preliminary testing to identify defective solar cells before final module assembly. By detecting defects early and marking them for replacement, the system prevents defective cells from being incorporated into the final product, thereby maintaining high reliability while establishing a framework for easy future replacements if needed.
3Reliability
If defective solar cells are found during production, then quality control is maintained, but replacing only the defective cell is difficult due to the integrated connection structure
Solution Approach 1:
The patent creates a segmented connection architecture where conductive wirings connect individual solar cells to intercell connectors in a modular fashion. This segmentation allows defective cells to be identified and replaced by simply disconnecting and reconnecting the conductive wirings at that specific location, without requiring disassembly of the entire module or affecting adjacent cells.
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
This approach enhances the yield rate, prevents output deterioration, and significantly improves the long-term reliability of solar cell modules by allowing for efficient replacement of defective cells and reinforcing the wiring structure.
Implementation Method 1
separating the target solar cell from the target string by selectively thermally processing a connection area of a target intercell connector among the plurality of intercell connector and a the plurality of conductive wirings fixed to the target solar cell in the target string
Implementation Method 2
coupling a new cell of connecting a plurality of the conductive wirings fixed to the new solar cell to the target intercell connector by selectively thermally processing an overlapping area of the target intercell connector and a plurality of the conductive wirings fixed to the new solar cell
Data Source
AI summary
A solar cell module and a method of manufacturing the same are provided. The method of manufacturing a solar cell module includes forming a plurality of strings to which a plurality of solar cells are connected; disposing a target string at a repair device, the target string including a target solar cell having a defect; separating the target solar cell from the target string by selectively thermally processing a connection area of a target intercell connector and the plurality of conductive wirings fixed to the target solar cell; disposing a new solar cell at the target string; and connecting the plurality of conductive wirings fixed to the new solar cell to the target intercell connector.