Solar Cell Interconnector Attachment Using Automated Clamping and Heating
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Solution Overview
Problem
The existing methods for attaching interconnectors to solar cell panels are complex and inefficient, leading to reduced productivity and long-term reliability issues, especially when using structures different from traditional ribbons.
Innovation Solution
An automated system comprising an interconnector fixing unit, a working table, and a heat source is used to attach interconnectors to solar cells, with a clamping unit that includes first and second clamps to securely fix and attach the interconnectors to the solar cells, improving the efficiency and stability of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ribbon attachment methods are used, then solar cells can be connected, but the apparatus and method become complex reducing productivity
Solution Approach 1:
The patent extracts the interconnector from the complex ribbon attachment process, using a separate dedicated attachment unit that clamps the interconnector between two solar cells. This simplifies the overall system by removing the need for complex ribbon handling apparatus while maintaining the essential connection function.
Solution Approach 2:
The interconnector acts as an intermediary component between solar cells, providing a simplified connection mechanism. The attachment unit uses this intermediary to establish connections without requiring complex direct bonding apparatus, thereby reducing device complexity while improving productivity.
2Adaptability or versatility
If interconnectors with different structure from ribbons are used, then new connection possibilities are enabled, but no attachment apparatus or method has been proposed
Solution Approach 1:
The attachment process is segmented into distinct functional units: an interconnector supply unit, a clamping unit with first and second clamps, and an attachment unit. This segmentation allows the system to handle different interconnector structures while maintaining ease of manufacture through modular, standardized operations.
Solution Approach 2:
The clamping unit is designed with universal functionality to accommodate different interconnector structures. The first clamp holds the interconnector before attachment, and the second clamp secures it during the bonding process, providing a versatile solution that works with various interconnector designs without requiring specialized apparatus for each type.
3Productivity
If automated system is implemented, then productivity is improved, but system complexity increases
Solution Approach 1:
The patent merges multiple functions into integrated units: the clamping unit combines holding and positioning functions, while the attachment unit integrates heating and bonding operations. This merging reduces the number of separate components needed, thereby improving productivity without proportionally increasing system complexity.
Solution Approach 2:
The automated system is designed to be self-contained, with the attachment unit performing all necessary operations (heating, bonding, cooling) without requiring external intervention or complex coordination systems. This self-service capability improves productivity while keeping the control system relatively simple.
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 automated system enhances productivity by simplifying the attachment process, improving the long-term reliability of solar cell panels by ensuring strong and stable connections between interconnectors and solar cells, thereby increasing the efficiency and output of the solar cell panel.
Implementation Method 1
a heat source for attaching the interconnectors and the solar cell to each other by applying heat to the interconnectors and the solar cell, which are fixed to each other
Data Source
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AI summary
Disclosed is a method for attaching an interconnector (142) of a solar cell panel (150). The method includes forming a first interconnector-jig coupling by fixing a plurality of first interconnectors to a jig (243), locating the first interconnector-jig coupling over a working table, fixing the first interconnectors and a first solar cell (150) to each other, separating the jig from the first interconnectors, and attaching the first interconnectors to the first solar cell by applying heat to the first interconnectors and the first solar cell, which are fixed to each other.