Solar Cell Power Routing Module for Automated Array Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar cell array assembly processes are manual, labor-intensive, and lack automation, making it difficult to customize and efficiently assemble long, variable-length strings of solar cells while maintaining high power generation efficiency.
Innovation Solution
A new design for solar cell arrays that attaches individual cells to a substrate with aligned corner regions, using corner conductors for electrical connections and a power routing module (PRM) to facilitate automated assembly and customization, allowing for flexible layout and efficient power routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly processes are used for solar cell arrays, then customization of layouts is possible, but productivity is low and labor intensity is high
Solution Approach 1:
The solar cell array is divided into modular CIC units (cell, interconnect, and coverglass assemblies) that can be independently manufactured and then automatically assembled. This segmentation enables both customization through selective arrangement of modules and increased productivity through automated assembly processes.
Solution Approach 2:
The patent changes the assembly parameters from manual handling of individual cells to automated handling of pre-assembled CIC modules. This parameter change enables automation while maintaining layout flexibility through programmable positioning of the modular units.
2Adaptability or versatility
If long strings of solar cells are assembled manually, then variable length configurations are achieved, but manufacturing precision and consistency deteriorate
Solution Approach 1:
By segmenting the array into standardized CIC modules with precise factory-prepared interconnects, the patent achieves consistent manufacturing precision for each module while allowing variable overall string lengths through automated selection and arrangement of the number of modules.
Solution Approach 2:
The interconnects and coverglass are pre-assembled to the cells in controlled factory conditions, ensuring manufacturing precision is established beforehand. This preliminary action allows automated assembly lines to simply position complete modules, maintaining precision across variable-length configurations.
3Reliability
If CIC units with parallel interconnects are used, then electrical connection is achieved, but device complexity increases for automated assembly
Solution Approach 1:
The electrical connection system is segmented into self-contained CIC modules where the interconnect geometry is standardized. This reduces the complexity of the overall assembly system while maintaining reliable electrical connections, as the automated assembly only needs to position modules rather than manipulate complex wiring.
Solution Approach 2:
The CIC module design creates a universal building block where the interconnect structure serves multiple functions: electrical connection, mechanical support, and alignment reference. This multi-functionality reduces assembly system complexity while ensuring reliable electrical connections.
4Reliability
If bypass diodes are added to protect cells from reverse bias, then reliability is improved, but manufacturing precision requirements increase for proper positioning
Solution Approach 1:
The bypass diodes are merged with the CIC module assembly process, where they are installed as part of the standardized module fabrication. This integration ensures consistent positioning precision is achieved during factory assembly rather than requiring field installation, improving both reliability and manufacturing efficiency.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A power routing module for electrically interconnecting solar cells in an array, wherein the power routing module includes: an electrically conductive layer for electrically interconnecting the solar cells; and an insulation layer for electrically insulating the electrically conductive layer. At least one of the solar cells has at least one cropped corner that defines a corner region. An area of a substrate in the corner region remains exposed when the solar cells are attached to the substrate, and the power routing module is attached to the substrate in the area of the substrate in the corner region that remains exposed.