Solar Cell Substrate Corner Conductors for Automated Array Assembly
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Solution Overview
Problem
Existing solar cell panel assembly processes are manual and difficult to automate due to the assembly of long, variable, and fragile solar cell strings, requiring highly customized layouts for maximum power generation, which complicates fabrication and increases costs.
Innovation Solution
A substrate-based approach where solar cells are individually attached with corner conductors on a substrate, allowing for electrical connections to be made in corner regions, enabling automated manufacturing and customization of solar cell arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual alignment and connection of CIC units with metal foil interconnects is used, then electrical connections between solar cells are achieved, but assembly automation is hindered and costs increase
Solution Approach 1:
The substrate includes pre-formed conductive elements (traces, pads, and interconnect structures) that are prepared in advance before solar cell attachment. These pre-formed conductive elements are positioned to align with the solar cell contacts, enabling automated assembly without manual alignment of interconnects.
Solution Approach 2:
The substrate serves multiple functions: it provides mechanical support for solar cells, contains pre-formed conductive elements for electrical connections, and includes alignment features for automated assembly. This multi-functional design eliminates the need for separate interconnect components and manual assembly procedures.
2Productivity
If customized assembly of variable-length solar cell strings is performed, then power generation efficiency is improved, but assembly time increases
Solution Approach 1:
The substrate is divided into multiple segments or modules, each capable of holding a specific number of solar cells. These modular segments can be independently manufactured and then assembled into variable-length strings by connecting multiple segments together, enabling both customization and automated assembly.
Solution Approach 2:
The substrate design allows for dynamic configuration of solar cell strings with variable lengths by selectively attaching or detaching modular segments. The pre-formed conductive elements are positioned to accommodate different string lengths while maintaining electrical continuity, enabling rapid reconfiguration without manual customization.
3Device complexity
If pre-formed conductive elements are included on the substrate, then electrical connections are simplified and automation enabled, but substrate complexity increases
Solution Approach 1:
The conductive elements (traces, pads, and interconnect structures) are integrated directly into the substrate structure, combining the substrate's mechanical support function with the electrical connection function. This merging eliminates the need for separate interconnect components and simplifies the overall assembly process for automation.
Solution Approach 2:
The substrate acts as an intermediary component that provides both mechanical support and electrical connectivity. The pre-formed conductive elements on the substrate serve as intermediaries between solar cell contacts, enabling automated assembly while managing the complexity of electrical interconnections through a standardized interface.
Data Source
AI summary
A substrate for solar cells is fabricated such that an area of the substrate remains exposed when at least one solar cell having at least one cropped corner that defines a corner region is attached to the substrate; the area of the substrate that remains exposed includes one or more conductors printed on the substrate; and electrical connections between the solar cell and the conductors are made in the corner region resulting from the cropped corner of the solar cell. The substrate may also include buried conductors for making series connections that determine a flow of power through a plurality of solar cells, including corner-to-corner and column-to-column connections for the plurality of solar cells that are attached to the substrate in a two-dimensional (2-D) grid of an array. The substrate may also be covered by a polyimide overlay for preventing electrostatic discharge (ESD).