Solar Cell String Electrode Overlap Bonding Without Conductive Members
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Solution Overview
Problem
Existing methods for producing solar cell strings using conductive members for electrode connections are not sufficiently productive and lack adequate adhesive force between electrodes.
Innovation Solution
A method involving the formation of first and second collector electrodes with different resin components, where the second electrode is softer and uncured, allowing them to be overlapped and cured for direct electrical connection, eliminating the need for additional conductive members and enhancing adhesive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conductive member is used to connect back-side bus bar electrode and front-side bus bar electrode, then electrical connection is achieved, but productivity is limited
Solution Approach 1:
The conductive member is merged with the resin layer to form an integrated structure. The conductive member is embedded in the resin layer such that the resin layer and conductive member work together as a unified connection system, eliminating the need for separate conductive components and improving productivity.
Solution Approach 2:
The resin layer serves multiple functions: it provides mechanical support, electrical insulation, and contains the conductive member for electrical connection. This multi-functional design reduces the number of separate components needed, thereby improving productivity and simplifying the connection structure.
2Strength
If conventional electrode connection method is used, then electrical connection is established, but adhesive force between electrodes is insufficient
Solution Approach 1:
The conductive member embedded in the resin layer acts as an intermediary between the back-side bus bar electrode and front-side bus bar electrode. This intermediary structure enhances adhesive force by creating a robust mechanical and electrical connection interface, while the integrated design maintains high connection efficiency.
Solution Approach 2:
The connection structure uses a composite material system combining resin layer and conductive member. This composite structure provides both mechanical bonding strength and electrical conductivity, enhancing adhesive force while maintaining connection efficiency through the synergistic properties of the combined materials.
3Strength
If more conductive members are added to increase adhesive force, then connection strength improves, but device complexity increases
Solution Approach 1:
Multiple conductive members are merged into a single integrated structure within the resin layer. This consolidation maintains connection strength by preserving the electrical connection function while reducing device complexity through the unified design of the resin layer containing embedded conductive members.
Solution Approach 2:
The resin layer serves as a universal component that simultaneously provides mechanical support, electrical insulation, and houses the conductive members for electrical connection. This multi-functional approach maintains connection strength while minimizing the number of separate components, thereby reducing device complexity.
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 method improves productivity and increases adhesive force between electrodes, resulting in enhanced connection strength and efficiency of solar cell strings.
Implementation Method 1
forming a first collector electrode by applying a first collector electrode material including a first resin component to one surface of a semiconductor substrate and curing the first collector electrode material
Implementation Method 2
forming a second collector electrode by applying a second collector electrode material including a second resin component softer than the first resin component to an other surface of the semiconductor substrate and leaving the second collector electrode material uncured; and curing the second collector electrode material
Implementation Method 3
curing the second collector electrode material after each two adjacent ones of the plurality of small cell pieces are partially overlapped with each other to allow the first collector electrode of one of each two adjacent small cell pieces to overlap the second collector electrode of an other one of each two adjacent small cell pieces
Data Source
AI summary
Provided is a method for producing a solar cell string including: preparing a plurality of small cell pieces by forming a first collector electrode by applying a first collector electrode material including a first metal component and a first resin component to one surface of a semiconductor substrate and curing the first collector electrode material, and forming a second collector electrode by applying a second collector electrode material including a second metal component and a second resin component softer than the first resin component to an other surface of the semiconductor substrate and leaving the second collector electrode material uncured; and curing the second collector electrode material after the first collector electrode of one of each two adjacent small cell pieces and the second collector electrode of an other one of each two adjacent small cell pieces overlap each other.