Solar Cell Module Wiring via Continuous Conductor Segmentation
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Solution Overview
Problem
Conventional methods for producing solar cell modules face challenges such as complex handling of shortened wiring materials, misalignment issues, limited production rate, lack of flexibility in electrode patterns, increased complexity, and waste generation due to the need for multiple wiring steps, especially with multi-wire structures.
Innovation Solution
A method where the cutting of linear conductors is performed after connecting the cell electrodes, allowing for the use of continuous conductors to connect solar cells in series, followed by electrical disconnection to form reliable connections, simplifying the process and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods use shortened wiring materials for connecting solar cells, then the wiring process can be completed, but the handling becomes complex and misalignment issues occur
Solution Approach 1:
The patent divides the wiring process into two distinct stages: first connecting continuous conductors to multiple solar cells, then cutting the conductors between cells. This segmentation transforms the complex handling of multiple shortened conductors into simpler operations with continuous conductors, reducing misalignment issues and handling complexity.
Solution Approach 2:
The patent performs the connection action before the cutting action. Continuous conductors are connected to solar cells first, establishing reliable electrical connections, and then the conductors are cut between cells. This preliminary connection approach ensures proper alignment and reduces handling complexity compared to pre-cutting conductors.
2Reliability
If multiple wiring steps are used for multi-wire structures, then comprehensive electrical connections are achieved, but waste generation increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple wiring operations into a single continuous conductor system. Instead of handling multiple separate shortened conductors, continuous conductors span across multiple solar cells, reducing material waste from cutting and handling while maintaining reliable electrical connections through the continuous structure.
Solution Approach 2:
The patent maintains the continuity of conductors throughout the connection process, allowing a single continuous conductor to serve multiple solar cells. This continuous approach eliminates the waste associated with cutting and discarding conductor portions, while the subsequent cutting between cells ensures proper electrical isolation and connection reliability.
3Productivity
If conventional wiring methods are used, then solar cells can be connected, but the production rate is limited due to complex handling
Solution Approach 1:
The patent segments the wiring process into connection and cutting phases, allowing continuous conductors to be connected to multiple cells in sequence without the time-consuming handling of individual shortened conductors. This segmentation significantly reduces wiring processing time and increases production rate.
Solution Approach 2:
The patent performs preliminary connections using continuous conductors before cutting, which reduces the time required for handling and positioning multiple shortened conductors. This preliminary connection approach streamlines the wiring process and enhances overall productivity.
4Ease of manufacture
If continuous conductors are used to connect solar cells, then the wiring process is simplified, but electrical disconnection between cells must be achieved
Solution Approach 1:
The patent segments the continuous conductor at specific locations between solar cells after connection. This segmentation approach maintains the simplicity of using continuous conductors for connection while achieving the necessary electrical disconnection through precise cutting between cells, balancing manufacturing simplicity with connection precision.
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 productivity of solar cell module production by simplifying the wiring process, reducing misalignment, and eliminating waste, while allowing for high-efficiency electrical connections between solar cells.
Implementation Method 1
wiring materials in the manner of interconnecting metal ribbons are soldered to electrodes formed on the surfaces of the solar cells, thereby forming electrical connections between adjacent solar cells
Data Source
AI summary
A method for producing a solar cell module is obtained that allows a wiring material to be wired by a highly productive wiring method when a solar cell module is formed by arranging the wiring material on an electrode of a solar cell. The method for producing a solar cell module includes preparing a plurality of solar cells having an electrode on at least one of a first main surface and a second main surface, arranging the plurality of solar cells so that the first main surfaces of the plurality of solar cells face roughly in the same direction, connecting the linear conductor for electrically connecting one of the electrode on the first main surface and the electrode on the second main surface of each solar cell with one continuous linear conductor, and electrically disconnecting the continuous linear conductor after the connecting the linear conductor so that the electrodes of at least one pair of adjacent solar cells among the plurality of solar cells are connected in series.