Solar Cell String Adhesive Wire Bonding Without Welding Stress

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Solution Overview

Problem

The current solar cell interconnection process involves high welding temperatures and stresses, which can be detrimental to photovoltaic modules, and the Smart wire interconnection technology increases process complexity and requires new equipment, making it costly and inefficient for mass production.

Innovation Solution

A method is developed where solar cells are directly electrically connected using wires laid across adjacent placement regions and bonded with adhesive layers, eliminating the need for prefabricated flexible electrical connection layers and welding, thereby reducing production costs and simplifying the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to connect solar cells, then electrical connection is achieved, but high welding temperatures and stresses damage the photovoltaic modules

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidwelding temperature and stress damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the welding process (thermal-mechanical system) with a mechanical bonding system using adhesive layers. The adhesive layers bond the conductive wires to the solar cells at room temperature or low temperature, eliminating the high temperature and stress damage caused by welding while maintaining reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces adhesive layers as intermediary substances between the conductive wires and solar cells. These adhesive layers serve as mediators that provide both mechanical bonding and electrical conductivity, replacing the direct thermal-mechanical welding process and protecting the solar cells from welding damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If Smart wire interconnection technology is used, then welding damage is avoided, but process complexity increases and specialized equipment is required

Engineering Contradiction:

Improvewelding damage avoidanceVSAvoidprocess complexity and equipment requirements

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent uses conventional adhesive layers and conductive wires that can be applied using existing manufacturing equipment. Instead of requiring specialized Smart wire equipment, the invention employs simple, readily available materials and processes that are already present in standard photovoltaic production lines, thereby reducing both equipment investment and process complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The adhesive layers serve multiple functions simultaneously: they provide mechanical bonding between wires and cells, ensure electrical conductivity, and protect the connection points. This multi-functionality eliminates the need for separate specialized equipment and processes, allowing existing manufacturing lines to produce the improved modules without additional complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If welding strip is used for interconnection, then manufacturing process is established, but production costs are high due to equipment and material requirements

Engineering Contradiction:

Improveinterconnection process establishmentVSAvoidproduction cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent uses conventional adhesive layer structures that are already well-established in photovoltaic manufacturing, copying the simple and proven application process. Instead of requiring new specialized materials or equipment, the invention uses standard adhesive layers and conductive wires that can be applied using existing manufacturing techniques, thereby maintaining ease of manufacture while reducing costs.

Inventive Principle:

Principle #26Copying

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 approach improves the performance of solar cell strings by avoiding adverse effects of high welding temperatures and stresses, simplifying the production process, and reducing production costs without the need for specialized equipment.

Implementation Method 1

providing a first adhesive layer, wherein each placement region of the first adhesive layer is used to bond and fix a corresponding solar cell

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4053921B1Solar cell string, photovoltaic module and manufacturing methods therefor

Publication Date: 2023.12.20 ZHEJIANG JINKO SOLAR CO LTD

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AI summary

A method for manufacturing a solar cell string includes: providing a first adhesive layer, wherein the first adhesive layer includes N placement regions being used for N solar cells respectively; placing the N solar cells on the placement regions; laying first wires on a surface of at least one solar cell away from the first adhesive layer, and stretching the first wires across adjacent placement regions to electrically connect two adjacent solar cells; disposing a second adhesive layer on the surface of the at least one solar cell of the N solar cells away from the first adhesive layer, wherein the first wires are located between the second adhesive layer and the at least one solar cell; performing a pressing treatment to bond and fix the first adhesive layer, the first wires, the at least one solar cell of the N solar cells and the second adhesive layer.