Solar Cell Strip Sorting for Shingled Module Consistency
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Solution Overview
Problem
The existing manufacturing process for shingled solar cell modules is inefficient due to inconsistencies in cell strips during the cell manufacturing process, leading to high labor intensity, increased costs, and a cracking risk, as well as repeated testing and sorting requirements.
Innovation Solution
A method and system for manufacturing solar cells and shingled solar cell modules that includes pretreatment, screen-printing, sintering and curing, scribing and dividing, and post-treatment steps, which involve texturization, junction diffusion, etching, and coating, followed by testing and sorting of solar cell strips to ensure consistency and reduce processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the legacy process flow is used where the entire cell is produced first and then scribed into strips in the module manufacturing process, then the cell manufacturing process can be completed, but repeated testing and sorting are required leading to high labor intensity and increased costs
Solution Approach 1:
The patent applies segmentation by dividing the solar cell manufacturing process into two distinct stages: cell manufacturing process and module manufacturing process. In the cell manufacturing process, the entire cell is produced and tested. In the module manufacturing process, the cell is then scribed into strips and assembled into modules. This segmentation allows each process to be optimized independently and reduces repeated handling.
Solution Approach 2:
The patent implements preliminary action by performing testing and sorting of solar cell strips during the cell manufacturing process before the module manufacturing process begins. This preliminary testing identifies and separates defective strips early, preventing them from entering the module assembly process, thereby reducing rework and improving overall manufacturing efficiency.
2Ease of manufacture
If cell strips are scribed and divided after cell manufacturing, then the cell can be produced, but inconsistencies from intra-cell differences require additional sorting steps increasing labor intensity
Solution Approach 1:
The patent applies self-service by implementing an automated testing and sorting system that automatically identifies and separates defective solar cell strips based on their electrical characteristics. The system performs IV testing and EL imaging automatically, eliminating the need for manual inspection and sorting, thereby reducing labor intensity while maintaining manufacturing simplicity.
3Reliability
If repeated testing and sorting are performed, then quality control can be maintained, but costs increase and cracking risk increases
Solution Approach 1:
The patent implements preliminary action by performing comprehensive testing (IV testing and EL imaging) and sorting of solar cell strips during the cell manufacturing process before module assembly. This preliminary quality control identifies and removes defective strips early, maintaining high reliability while reducing the need for repeated handling that could cause cracking.
Solution Approach 2:
The patent applies the extraction principle by removing defective solar cell strips from the production flow through automated sorting based on electrical characteristics. Defective strips are extracted and separated from good strips, preventing them from entering the module assembly process. This reduces the need for rework and minimizes handling that could cause cracking, thereby maintaining quality control while reducing cracking risk.
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 enables a smooth manufacturing flow, reduces repeated processing, lowers costs, and optimizes the appearance and color consistency of shingled solar cell modules by integrating testing and sorting directly into the cell manufacturing process.
Implementation Method 1
a scribing device configured to divide the solar cell into a plurality of strips by scribing lines through the solar cell
Implementation Method 2
a first sorting device configured to sort the plurality of strips into first groups and second groups based on electrical characteristics of the strips determined through IV testing
Implementation Method 3
a second sorting device configured to sort the plurality of strips into third groups and fourth groups based on light emission characteristics of the strips determined through EL imaging
Implementation Method 4
a screen-printing device configured to print a conductive paste onto the solar cell
Implementation Method 5
a sintering device configured to screen-print the solar cell
Data Source
AI summary
The present disclosure provides a method and system for manufacturing solar cells and shingled solar cell modules. The method as provided by the present disclosure includes performing scribing and dividing of the solar cells, sorting the obtained solar cell strips, and packaging the cell strips in the solar cell manufacturing process. The solar cell strips can be assembled directly after dismantling the package in the solar module manufacturing process. Therefore, the method can accomplish a smooth flow of manufacturing solar cells and shingled solar cell modules, reduce repeated processing steps, lower the risk of cracking and costs thereof, and optimize the current matching and the color consistency of the cell strips in the shingled solar cell modules.