Solar Cell Wiring via Twisted Adhesive Strip
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Solution Overview
Problem
Conventional methods for connecting solar battery cells, such as using solder, face issues with high temperature-induced damage, complexity in the production process, and reduced yield due to dimensional inaccuracies, while solder-free methods like conductive adhesives complicate the production process and reduce productivity.
Innovation Solution
A method involving a strip-like conductive substrate with an adhesive layer, where one end is bonded to a solar battery cell's electrode and the other end is turned around to connect with an adjacent cell's electrode of opposite polarity, simplifying the connection process and allowing for high-reliability solar battery modules at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder is used for connecting electrodes with wiring members, then connection reliability and adhesive strength are improved, but high temperatures cause fracture and warpage of solar battery cells
Solution Approach 1:
The patent changes the connection temperature parameter from soldering temperatures (230-260°C) to lower temperatures (100-200°C) by using conductive adhesive materials that can form reliable electrical connections without requiring high heat, thereby preventing cell fracture and warpage while maintaining connection reliability
Solution Approach 2:
The patent replaces the thermal-mechanical soldering process with a chemical-adhesive bonding process. Instead of using heat and molten metal to create connections, the invention uses conductive adhesive materials that bond through adhesion and curing, eliminating the harmful thermal effects on solar battery cells
2Strength
If solder is used for connecting electrodes, then connection strength is improved, but dimensional accuracy deteriorates due to difficulty in controlling distance between electrode and wiring member
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductive adhesive layer on the wiring member or electrode surface before the actual connection process. This pre-formed layer serves as a spacer and bonding medium that automatically maintains the required dimensional accuracy and distance control between components, eliminating the need for complex positioning during soldering
3Object-affected harmful factors
If conductive adhesive is used for connecting electrodes without solder, then temperature-related damage is reduced, but production process becomes complicated
Solution Approach 1:
The patent merges multiple steps into one by combining the adhesive application, alignment, and bonding operations into a single integrated process. The conductive adhesive layer is applied in advance, and subsequent steps involve simple placement and curing, eliminating the need for separate heating, positioning, and bonding steps required in traditional soldering processes
4Object-affected harmful factors
If conductive adhesive is used for connecting electrodes, then productivity is reduced due to repeated processes for each electrode
Solution Approach 1:
The patent creates a universal wiring member structure with pre-formed conductive adhesive layers that can be used for connecting multiple different electrodes (front-face and back-face electrodes of various solar battery cells) through the same process, eliminating the need for separate specialized procedures for each electrode type and significantly improving productivity
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 method simplifies the production process, enhances the reliability and yield of solar battery modules, and mitigates the adverse effects of high temperatures and humidity, while maintaining dimensional accuracy and impact resistance.
Implementation Method 1
a wiring member including a strip-like conductive substrate and an adhesive layer provided on one face of the conductive substrate
Data Source
AI summary
A method of connecting solar battery cells, each provided with a front-face and a back-face electrode, comprises: preparing a wiring member including a strip-like conductive substrate and an adhesive layer provided on one face of the substrate, and bonding the adhesive layer on one end portion of the wiring member with the front-face electrode or the back-face electrode of one cell; turning an other end portion of the wiring member having completed the above preparation, around a central axis along a longitudinal direction so an adhesive layer surface of the other end portion is opposite in orientation to an adhesive layer surface of the one end portion; and then bonding the adhesive layer of the other end portion of the wiring member with an electrode of another solar battery cell having an opposite polarity to the electrode of the one cell previously bonded in the aforementioned preparation process.