Solar Cell Module Wiring Members
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Solution Overview
Problem
The existing methods for connecting solar cells in solar cell modules result in increased panel size due to the use of wide ribbons, which lead to light losses and require new production equipment, thereby increasing production costs and reducing price competitiveness.
Innovation Solution
A solar cell module design that uses thin, wire-shaped wiring members with a core layer and solder layer to connect divided solar cells, reducing the distance between cells and maintaining output efficiency without requiring new equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wide ribbons are used to connect solar cells, then the connection strength is improved, but the panel size increases and light losses occur
Solution Approach 1:
The patent changes the dimensional parameters of the wiring member by transitioning from wide ribbons to thin wire-shaped structures with specific diameter ranges (0.5-2.0 mm), thereby reducing the area occupied while maintaining connection functionality through optimized geometric parameters
Solution Approach 2:
The patent employs composite material structures in the wiring members, combining metal cores with solder layers or coating materials, which enables the thin wire structure to achieve sufficient mechanical strength and electrical conductivity without increasing panel size
2Reliability
If the number of wiring members is increased to reduce carrier moving distances, then the electrical characteristics are improved, but the panel size increases
Solution Approach 1:
The patent optimizes the diameter parameter of wiring members to specific ranges (0.5-2.0 mm) that enable closer spacing between solar cells, allowing more wiring members to be accommodated within the same panel area without increasing overall panel dimensions
Solution Approach 2:
The patent transitions from two-dimensional ribbon connections to three-dimensional wire-shaped connections, enabling wiring members to be routed through space more efficiently and positioned closer to solar cell contacts, thereby increasing the effective number of connections within the same panel footprint
3Area of stationary object
If thin wire-shaped wiring members are used, then the panel size is reduced, but the wiring members are difficult to bend and warp
Solution Approach 1:
The patent uses composite material structures where metal cores provide structural support and flexibility, while outer solder layers or coating materials provide ductility and ease of formation, enabling thin wire-shaped wiring members to be bent and shaped during manufacturing without breaking or warping
Solution Approach 2:
The patent specifies optimal diameter ranges (0.5-2.0 mm) for the wiring members that balance flexibility for bending during assembly with structural integrity, and controls the thickness ratio between core and coating layers to achieve appropriate mechanical properties for both bending and final positioning
4Reliability
If divided solar cells are used instead of mother solar cells, then the output efficiency is improved, but new production equipment is required
Solution Approach 1:
The patent designs wiring members with standardized dimensions and connection methods that can be used with both mother solar cells and divided solar cells, allowing existing production equipment to handle both cell types without modification, thereby enabling manufacturers to produce high-efficiency divided cell modules using current equipment
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
The solution effectively reduces the size of the solar cell module, minimizes light losses, and maintains output efficiency while allowing production using existing equipment, thus enhancing productivity and cost-effectiveness.
Implementation Method 1
a solder layer which surrounds a surface of the core layer and is formed of a solder material
Data Source
AI summary
Discuss is a solar cell module including a plurality of solar cells having a long axis and a short axis, each solar cell including a first electrode disposed on a front surface and a second electrode disposed on a back surface thereof, and the plurality of solar cells being disposed along a first direction, and a plurality of wiring members connected to the first electrode of a first solar cell and the second electrode of a second solar cell adjacent to the first solar cell among the plurality of solar cells, wherein a thickness of the plurality of wiring members is approximately 270 μm to 320 μm.