Solar Cell Stringing with Extended Conductor Strip
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Solution Overview
Problem
Existing methods for producing solar cell strings are inefficient and require special starter and end conductor pieces, limiting automation and increasing production time.
Innovation Solution
A method using conductor strips of two lengths, where the extended conductor strip connects the last solar cell of one string to the first of the next, allowing continuous production without the need for special starter and end pieces, and a device with a separating station to cut the extended strip, optimizing the process flow and increasing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If special starter and end conductor pieces are used for each solar cell string, then the production process can be completed, but the production time increases and automation is limited
Solution Approach 1:
The patent merges the function of multiple conductor strips into a single continuous extended conductor strip that connects multiple solar cells across string boundaries. This eliminates the need for separate starter and end conductor pieces, enabling continuous production without stopping to attach special conductor pieces for each string, thereby increasing productivity and reducing production time.
Solution Approach 2:
The extended conductor strip enables continuous stringing operations by maintaining electrical connectivity across multiple solar cells and string boundaries without interruption. The conveyor system continuously transports solar cells through the stringing process, and the extended conductor strip maintains this continuous action by spanning across what would traditionally be discrete string segments, eliminating idle time between string completions.
2Ease of manufacture
If special starter and end conductor pieces are used for each solar cell string, then complete strings can be produced, but the device complexity increases
Solution Approach 1:
The extended conductor strip serves multiple functions: it acts as a regular conductor strip within a string, serves as a starter piece for the next string, and functions as an end piece for the previous string. This multi-functionality eliminates the need for separate special conductor pieces, simplifying the manufacturing process and reducing device complexity while maintaining ease of production.
3Extent of automation
If traditional methods with separate conductor pieces are used, then each string can be independently assembled, but the automation extent is reduced
Solution Approach 1:
The extended conductor strip is pre-configured to span across multiple solar cells and string boundaries before the stringing process begins. This preliminary preparation allows the automated conveyor system to continuously place solar cells onto the pre-positioned conductor strip without requiring complex real-time adjustments or interventions for starting and ending each string, thereby increasing automation extent while maintaining ease of operation.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
To produce solar cell strings (11, 12), solar cells (1, 1', 1") are first connected to each other by conductor strips (5) of a first length (L) until a desired number of solar cells (1, 1', 1") are available to produce a first solar cell string (11). Then, another solar cell (2) is connected to the last solar cell (1") of the first solar cell string (11) by an extended conductor strip (7). This additional solar cell (2) is spaced further (t) away from the last solar cell (1") than the string cell spacing (s). This additional solar cell (2) forms the first solar cell for a second solar cell string (12).The extended conductor strip (7) is separated to decouple the first solar cell string (11) in such a way that an intermediate piece is cut out when the extended conductor strip (7) is separated, whereby the remaining, opposing residual conductor strip sections (24, 25) after the separation of the extended conductor strip (7) correspond in terms of length to a beginning or end conductor section (4) of a solar cell string (11).