Solar Cell Substrate Surface Routing for Structural Integrity
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Solution Overview
Problem
Conventional solar cell modules require through holes in the substrate to accommodate bus bars and connection wires, which complicates manufacturing and may compromise the structural integrity of the apparatus.
Innovation Solution
The solar cell apparatus features a design where the junction box, bus bars, connection wires, and diode are placed on the top surface of the substrate, eliminating the need for through holes and enhancing the structural strength by securely attaching the junction box to the frame and allowing the use of a protective substrate to absorb physical shocks and prevent moisture infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If through holes are formed in the substrate to accommodate bus bars and connection wires, then the electrical connection function is achieved, but the manufacturing complexity increases and structural strength deteriorates
Solution Approach 1:
Instead of passing bus bars and connection wires through holes in the substrate from one side to the other, the invention inverts the approach by having these components terminate at the back surface of the substrate. The connection wires are then routed along the back surface to connect to the junction box, eliminating the need for through holes and preserving substrate integrity.
Solution Approach 2:
The invention transitions from a three-dimensional through-hole routing approach to a two-dimensional surface routing approach. Connection wires are routed along the back surface of the substrate rather than penetrating through it, changing the dimensional path from volumetric to surface-level, thereby avoiding substrate penetration and maintaining structural strength.
2Device complexity
If through holes are formed in the substrate, then bus bars can extend to the bottom surface for connection, but the manufacturing process becomes complicated
Solution Approach 1:
The invention extracts the connection function from the substrate interior to the substrate exterior. Instead of routing wires through the substrate thickness, the connection wires are extracted to the back surface where they can be connected to the junction box, simplifying the manufacturing process by eliminating hole formation steps.
3Strength
If the junction box is attached to the top surface of the substrate, then the outer appearance is improved and manufacturing is simplified, but the attachment security may be compromised
Solution Approach 1:
The frame is designed with preliminary attachment structures (such as clips or mounting points) that are pre-configured to securely hold the junction box on the back surface. This preliminary preparation ensures secure attachment without requiring complex additional components or steps during assembly.
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 design simplifies the manufacturing process and improves the mechanical strength of the solar cell module by eliminating the need for through holes and securely attaching the junction box, while maintaining efficient energy conversion and protection of the solar cells.
Implementation Method 1
A solar cell module for converting photo energy into electric energy through the photoelectric transformation
Data Source
AI summary
Disclosed is a solar cell apparatus. The solar cell apparatus includes a first substrate including a first region and a second region adjacent to the first region, a plurality of solar cells in the first region, and a second substrate provided in the first region to expose the second region and provided on the solar cells.