Solar Cell Module Insulation Grooves to Prevent Submodule Shorts
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Solution Overview
Problem
The existing insulation line in solar cell modules, as disclosed in PTL 1, has room for improvement in terms of efficiency and reliability.
Innovation Solution
A solar cell module with a new inter-submodule insulation structure, featuring two base plates with conductive layers and insulating grooves that define insulating spaces to prevent short circuiting between adjacent submodules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic vibration is used to fuse base plates between submodules, then submodules can be electrically connected in series, but insulation between adjacent submodules is insufficient and short circuiting may occur
Solution Approach 1:
The base plate is segmented by forming insulating grooves that divide it into multiple regions. These grooves create physical separation between adjacent submodules, establishing reliable insulation while maintaining the overall structural integrity needed for production efficiency.
Solution Approach 2:
Insulating grooves act as intermediary elements between adjacent submodules. These grooves introduce an insulating medium (the groove structure itself) that prevents direct electrical contact between submodules, thereby ensuring insulation reliability without compromising the series connection functionality.
2Ease of manufacture
If conventional insulation structures are used, then manufacturing is simple, but insulation effectiveness is insufficient and misalignment causes short circuits
Solution Approach 1:
Insulating grooves are formed in advance during base plate manufacturing, before the submodule assembly process. This preliminary action ensures that insulation structures are already in place and properly positioned, preventing short circuits even if minor misalignments occur during subsequent assembly steps.
Solution Approach 2:
The insulating grooves provide a buffer or cushioning effect against potential misalignment. By having the insulation structure pre-established with sufficient width and depth, the design accommodates minor positioning errors without compromising insulation effectiveness, thus cushioning against manufacturing variability.
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 structure enhances production efficiency and ensures reliable insulation between submodules, even in cases of misalignment during the bonding process.
Implementation Method 1
upper and lower film substrates are fused by ultrasonic vibration between series-connected adjacent submodules to form a fusion part that functions as an insulation line
Data Source
AI summary
A solar cell module comprises: two base plates each including a conductive layer on at least one side; and a plurality of submodules interposed between respective conductive layers of the two base plates. The plurality of submodules each include a plurality of cells connected to each other as a result of a conductive material electrically connecting the respective conductive layers of the two base plates. The two base plates each have a plurality of insulating grooves in a gap between the plurality of submodules. The plurality of insulating grooves of one of the two base plates and the plurality of insulating grooves of an other one of the two base plates define at least one insulating space that prevents short circuiting between adjacent submodules.