Solar Cell Panel Wiring Overlap Structure for Thermal Reliability
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Solution Overview
Problem
Solar cell panels face reliability and productivity issues due to wiring connections that are prone to separation when expanded and contracted with temperature changes, especially when wirings are positioned on one surface and extend across multiple cells, leading to reduced output and high defect rates.
Innovation Solution
A solar cell panel design featuring first and second extension wirings that overlap to form a connection portion, with the second extension wiring of one solar cell overlapping the first extension wiring of another, and a fixing portion to secure the connection, allowing for improved connection characteristics and structural stability without intersecting wires, thus simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wirings are formed to extend long across two solar cells, then electrical connectivity between cells is achieved, but the wirings are prone to separation due to thermal expansion and contraction, reducing reliability
Solution Approach 1:
The patent divides the wiring system into separate segments: individual wirings for each solar cell and distinct bridge wirings for inter-cell connections. This segmentation prevents long continuous wirings from experiencing thermal stress, eliminating separation issues while maintaining electrical connectivity between cells.
Solution Approach 2:
The patent introduces bridge wirings as intermediary elements that connect individual cell wirings. These bridge wirings act as mediators between adjacent solar cells, providing stable inter-cell connectivity without requiring long spanning wirings that would be susceptible to thermal expansion and contraction.
2Reliability
If separate bridge wirings are added to connect wirings of adjacent solar cells, then connection reliability improves, but material costs increase and manufacturing process becomes complicated
Solution Approach 1:
The patent merges the functions of individual cell wirings and inter-cell bridge wirings into a single integrated wiring structure. The bridge wirings are formed as separate elements that connect to individual cell wirings, simplifying the overall structure while maintaining reliability. This merging approach eliminates the need for complex intersecting wiring patterns.
3Ease of manufacture
If wirings are positioned on only one surface of the solar cell, then manufacturing process is simplified, but connection characteristics deteriorate and long-term reliability is reduced
Solution Approach 1:
The patent transitions from a two-dimensional surface-level wiring arrangement to a three-dimensional structure by having wirings extend from one surface, through the cell, to the opposite surface. This dimensional change allows wirings to be positioned on one surface during manufacturing while achieving robust connections that pass through the cell body, improving long-term reliability without complicating the positioning process.
Data Source
AI summary
According to a solar cell panel according to the present embodiment, a connection structure of a wiring unit for connecting a plurality of solar cells comprising first and second solar electrically connected to each other is improved. More particularly, the wiring unit comprises a first extension wiring and a second extension wiring, which correspond to each of the plurality of solar cells, the first extension wiring having a first outer portion extending outwards beyond a first side of a solar cell and a second extension wiring having a second outer portion extending outwards beyond a second side of the solar cell, the second side being opposite to the first side of the solar cell. A second extension wiring of the first solar cell and a first extension wiring of the second solar cell overlap each other to have a connection portion where they are connected to each other, and the connection portion includes an overlapping portion formed by the connection portion overlapping a portion of the first solar cell.