Solar Cell Wiring via Stress-Distributing Conductive Paste
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Solution Overview
Problem
Solar cells in portable electronic devices face challenges in achieving both thinness and high power generation efficiency while maintaining electrostatic resistance, as existing methods concentrate stress on specific points, leading to damage and reduced insulation.
Innovation Solution
A manufacturing method involving a conductive paste with fine particles dispersed in an adhesive material, applied between the power generating film and the wiring member through an anisotropic conductive film, which distributes stress evenly and prevents concentration, thereby enhancing electrostatic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the power generating film is pressed and heated to fix the wiring member through the anisotropic conductive film, then the wiring member is firmly attached, but stress is concentrated by the conductive particles causing damage to the power generating film and reduced electrostatic resistance
Solution Approach 1:
A resin layer is introduced as an intermediary between the power generating film and the anisotropic conductive film. This resin layer acts as a stress-distributing medium that prevents stress concentration at the conductive particles, while still allowing the anisotropic conductive film to provide electrical connection and adhesive bonding functions.
Solution Approach 2:
The resin layer is placed in advance between the power generating film and the anisotropic conductive film to cushion and distribute the stress that will occur during pressing and heating. This pre-positioned cushioning layer prevents direct stress transmission to the power generating film, thereby maintaining its integrity and electrostatic resistance.
2Ease of manufacture
If the power generating film is pressed to fix the wiring member, then the wiring member is securely bonded, but the power generating film is damaged leading to decreased electrostatic resistance
Solution Approach 1:
The resin layer serves as a mediator between the pressing force and the power generating film, distributing the mechanical stress evenly across the interface. This allows secure bonding of the wiring member through the anisotropic conductive film while protecting the power generating film from damage.
Solution Approach 2:
The resin layer changes the stress distribution parameters by transforming concentrated point stresses from the conductive particles into distributed areal stresses, thereby reducing the peak stress values that cause damage to the power generating film during the bonding process.
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 method effectively improves electrostatic resistance by averaging stress distribution, preventing damage to the power generating film and ensuring reliable insulation, even when subjected to static electricity.
Implementation Method 1
the conductive paste, stress is prevented from being biased to a specific position. Accordingly, the stress is not concentrated on a specific position of the power generating film
Implementation Method 2
a distribution of a stress applied to the power generating film is averaged by the conductive paste
Implementation Method 3
the power generating film is irradiated with light, the power generating film is excited by the light, and thus electric current flows
Data Source
AI summary
A conductive paste is disposed on a transparent conductive film of a substrate in which a power generating film and the transparent conductive film are disposed in this order, a wiring member is disposed on the conductive paste through an anisotropic conductive film, and the anisotropic conductive film is heated while pressing the substrate and the wiring member by interposing them, and thus the wiring member is fixed.