Solar Cell Tab Wire Cover Fixing via Encapsulant Slit

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Solution Overview

Problem

In solar cell module manufacturing, the cover used to hide connecting tab wires can dislocate during the manufacturing process due to the inability to fix it with tape, compromising the module's reliability and appearance.

Innovation Solution

A method involving the use of a first and second encapsulant between protective members, with solar cells in between, where the connecting tab wire cover and encapsulant are fixed with adhesive tape through a slit in the encapsulant, ensuring the cover remains in place and hides the tab wires effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the encapsulant is made larger than the cover to improve reliability, then the cover cannot be fixed with tape, but the cover may dislocate during manufacturing

Engineering Contradiction:

Improvemodule reliabilityVSAvoidcover position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent introduces a connecting tab wire encapsulant as an intermediary component between the cover and the main encapsulant. This intermediary element provides a dedicated structure that can be fixed with tape, thereby maintaining both the reliability benefit of a larger encapsulant and the stability benefit of being able to secure the cover in place during manufacturing processes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If the cover is used to hide the connecting tab wires, then the appearance is improved, but the cover dislocates during manufacturing compromising reliability

Engineering Contradiction:

Improveappearance qualityVSAvoidmodule reliability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The connecting tab wire encapsulant serves as a mediator that connects the cover to the main encapsulant through tape fixation. This ensures the cover remains properly positioned to hide the connecting tab wires for aesthetic purposes while simultaneously maintaining manufacturing reliability through secure fixation

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Prevents cover dislocation, maintains module reliability, and improves the aesthetic appearance by keeping tab wires concealed, while simplifying the manufacturing process and reducing costs.

Implementation Method 1

fixing members that fix, through a slit formed on the connecting tab wire encapsulant, the connecting tab wire cover and a connecting tab wire... The fixing members comprise a first adhesive tape that fixes the connecting tab wire cover and the connecting tab wire encapsulant

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP3188254B1Manufacturing method for solar cell module and solar cell module manufactured by same

Publication Date: 2019.11.20 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

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AI summary

In a solar cell module (100), a first encapsulant (12) and a second encapsulant (24) are provided between a first protective member (10) and a second protective member (26), and solar cells (18) are provided between the first encapsulant (12) and the second encapsulant (24). A connecting tab wire cover (14) is laminated on the first encapsulant (12). A connecting tab wire encapsulant (16) is laminated on the connecting tab wire cover (14). The multiple solar cells (18) are laminated on the first encapsulant (12). Through a slit formed on the connecting tab wire encapsulant (16), fixing members fix a connecting tab wire, which connects multiple solar cells (18), and the connecting tab wire cover (14).