Photovoltaic Module Pad Geometry for Stable Solder Strip Bonding
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Solution Overview
Problem
Conventional photovoltaic modules suffer from poor reliability due to dummy bonding between the pad and the solder strip, leading to operational inefficiencies.
Innovation Solution
A photovoltaic module design featuring a solder strip connected through fasteners to a pad with specific dimensions and shapes, including a second part with a narrower width than the first and third parts, and a symmetrical connection structure, along with a laminated assembly using adhesive films and a back sheet, to enhance stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pad and solder strip connection structure is used, then the manufacturing process is simple, but the connection reliability is poor due to dummy bonding
Solution Approach 1:
The pad is divided into three distinct parts: a first part, a second part with narrower width, and a third part. This segmentation creates a structured configuration that guides the solder strip connection, preventing dummy bonding by ensuring proper alignment and contact between the solder strip and pad through the narrowed second part region.
2Reliability
If the pad width is uniform throughout, then the manufacturing is easier, but the connection stability between solder strip and pad is reduced
Solution Approach 1:
The pad exhibits local quality variation through its width changes: the second part has a narrower width compared to the first and third parts. This localized narrowing creates a specific geometric feature that enhances connection stability by providing a defined contact region for the solder strip, while the rest of the pad maintains sufficient width for other functional requirements.
3Reliability
If fasteners are not used in the connection, then the manufacturing process is simpler, but dummy bonding occurs frequently reducing operational reliability
Solution Approach 1:
Fasteners are introduced as intermediary elements between the pad and solder strip. These fasteners serve as mediators that secure the connection, preventing dummy bonding by ensuring proper alignment and mechanical attachment. The fasteners bridge the gap between the pad structure and solder strip, providing a reliable connection mechanism.
4Stability of the object's composition
If adhesive films are not used in the assembly, then the manufacturing is simpler, but the deformation of components increases during operation
Solution Approach 1:
Adhesive films are used as flexible thin film elements in the assembly. These films provide bonding between components while accommodating thermal expansion and mechanical stress, reducing deformation during operation. The adhesive films create a stable assembly structure by adhering the light-transmitting member, back sheet, and other components to the solar cell string.
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 design improves operational reliability and extends the service life of the photovoltaic module by reducing material consumption, minimizing deformation of adhesive films, and ensuring stable connections between the solder strip and pad.
Implementation Method 1
The solder strip is connected to the pad through the fastener to form a solar cell string
Implementation Method 2
The adhesive films are arranged on two sides of the solar cell string along a thickness direction of the solar cell string
Implementation Method 3
A photovoltaic module is a device that utilizes clean energy for power generation
Data Source
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AI summary
A photovoltaic module and a method for manufacturing photovoltaic module. The photovoltaic module includes a solar cell, a pad, fasteners, and a solder strip. The pad is arranged on the solar cell and includes first, second, and third parts, the first part is connected to the third part through the second part, and along a length direction of the solder strip, a width of the second part is less than a width of the first part and a width of the third part. The fasteners are arranged on a side of the first part facing away from the solar cell and a side of the third part facing away from the solar cell, the solder strip is provided between the fastener in the first part and the fastener in the third part, and the solder strip is connected to the pad through the fastener to form a solar cell string.