Reflective Solder Strip Structure for Uniform Solar Module Soldering
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Solution Overview
Problem
Existing solder strips for photovoltaic modules face challenges in efficiently reflecting sunlight for photoelectric conversion and preventing solder layer agglomeration, leading to reduced power output and increased costs due to inefficient design and material usage.
Innovation Solution
A solder strip with a specific cross-sectional structure featuring a base portion and a reflective portion with acute angles greater than 42.5°, a copper substrate, and a solder layer, designed to enhance light reflection and prevent agglomeration by optimizing the angles and structure to ensure total reflection and uniform solder distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the solder strip uses a conventional rectangular cross-section, then the manufacturing process is simple, but the light reflection efficiency is insufficient and solder layer agglomeration occurs
Solution Approach 1:
The solder strip cross-section is segmented into three distinct portions: a flat portion, a reflective portion, and a rounded portion. This segmentation allows each portion to serve its specific function - the flat portion provides a stable base, the reflective portion optimizes light reflection with acute angles greater than 42.5°, and the rounded portion prevents solder agglomeration, thereby resolving the contradiction between manufacturing simplicity and light reflection efficiency.
Solution Approach 2:
Different portions of the solder strip are given different geometric qualities tailored to their specific functions. The reflective portion features acute angles optimized for total light reflection, while the rounded portion has a curved surface to prevent solder agglomeration. This local differentiation of geometric properties enables the solder strip to simultaneously achieve efficient light reflection and reliable solder distribution without compromising manufacturing feasibility.
2Device complexity
If the solder strip uses a conventional rectangular cross-section, then the structure is simple, but solder layer distribution is non-uniform and agglomeration occurs
Solution Approach 1:
The cross-section is divided into distinct portions with the rounded portion specifically designed to guide solder layer distribution. The rounded geometry creates a natural flow path that prevents agglomeration and ensures uniform solder distribution across the solar cell surface, while the overall structure remains relatively simple with only three main portions.
Solution Approach 2:
The rounded portion of the solder strip introduces a curved surface geometry that replaces the sharp edges of a conventional rectangular cross-section. This curvature prevents the solder layer from accumulating at corners and edges, directing it instead to spread evenly across the solar cell surface, thereby improving solder distribution uniformity while maintaining structural simplicity.
3Reliability
If the solder strip uses acute angles greater than 42.5° in the reflective portion, then total light reflection is achieved, but the manufacturing precision requirement increases
Solution Approach 1:
The patent specifies a particular angular parameter range (greater than 42.5°) for the reflective portion that enables total light reflection. This parameter optimization balances the need for high reflection efficiency with manufacturability, as angles in this range can be achieved through conventional manufacturing processes without requiring extremely tight tolerances, thus resolving the contradiction between reflection efficiency and manufacturing precision.
4Volume of moving object
If the solder strip height is reduced to less than or equal to 0.3 mm, then the module assembly is more compact, but the structural strength may be compromised
Solution Approach 1:
The solder strip is segmented into portions with different height characteristics. The flat portion provides a stable base with sufficient height for structural support, while the reflective and rounded portions are optimized for their specific functions. This segmentation allows the overall height to be controlled at ≤0.3 mm for compactness while maintaining adequate structural strength through the distributed geometry of the different portions.
Solution Approach 2:
Different portions of the solder strip are given different local geometric qualities that optimize both compactness and strength. The base portion has sufficient height and width for structural support, while the reflective and rounded portions are more compact. This local differentiation of geometric properties enables the solder strip to achieve overall compactness (height ≤0.3 mm) while maintaining structural strength through the reinforced base portion.
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 solution increases the power output of photovoltaic modules by improving light reflection and reducing solder layer agglomeration, thereby enhancing the efficiency and cost-effectiveness of the solar cell module production.
Implementation Method 1
A first angle is formed between the first side edge and an extension line of the top edge, and a second angle is formed between the second side edge and the extension line of the top edge. The first angle and the second angle are both acute angles formed in a range greater than 42.5°... to enhance light reflection and reducing solder layer agglomeration, thereby enhancing the efficiency
Data Source
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AI summary
Provided is a solder strip. A cross section of the solder strip includes a base portion and a reflective portion arranged above the base portion. The reflective portion includes a top edge, a first side edge and a second side edge. A first angle is formed between the first side edge and an extension line of the top edge. A second angle is formed between the second side edge and the extension line of the top edge. The first angle and the second angle are greater than 42.5°. Compared with the related art, a reflective portion having a first side edge and a second side edge is formed on the solder strip, the first angle and the second angle are acute angles greater than 42.5°, sunlight strikes the first side edge and the second side edge of the reflective portion to form reflected light, and the reflected light incident on the solder strip may be totally reflected at a glass and air interface layer of a photovoltaic module, so that the sunlight totally reflected re-participates in photoelectric conversion and thus improves the utilization of the reflected light.