Staggered Slit Solar Cell Interconnect for Strain Relief

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Solution Overview

Problem

Existing solar cell interconnects face a challenge in providing sufficient strain relief without increasing electrical path resistance, as longer slits for strain relief can lead to efficiency losses due to increased electrical resistance.

Innovation Solution

The design incorporates in-plane slits arranged in multiple rows, with a staggered configuration that keeps the middle slit relatively short to minimize electrical path lengths while adding slits in other rows for enhanced strain relief, maintaining low electrical resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If longer slits are used for strain relief, then strain relief is improved, but electrical path resistance increases

Engineering Contradiction:

Improvestrain reliefVSAvoidelectrical path resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The interconnect is divided into multiple rows of slits rather than using a single long slit. This segmentation allows strain relief to be distributed across multiple shorter slits in different rows, preventing the formation of a single long electrical path that would increase resistance. The current can flow through multiple parallel paths between the slits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slit configuration transitions from a one-dimensional single slit to a two-dimensional multi-row staggered pattern. This dimensional change allows strain relief to be achieved in multiple directions while maintaining short electrical path lengths through the staggered arrangement that creates multiple current flow paths.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If multiple rows of slits are added, then strain relief is enhanced, but device complexity increases

Engineering Contradiction:

Improvestrain reliefVSAvoidslit configuration complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The slits are arranged in a staggered asymmetric pattern rather than a symmetric grid. This asymmetric staggering provides effective strain relief in multiple directions while maintaining a relatively simple manufacturing process. The pattern is regular enough to be manufactured efficiently but asymmetric enough to provide multi-directional strain relief.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Different regions of the interconnect have slits arranged in specific patterns optimized for local strain relief needs. The staggered multi-row configuration provides varying slit densities and orientations in different areas, allowing targeted strain relief where needed while maintaining overall structural integrity and electrical performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9691924B1Solar cell interconnect with multiple current paths

Publication Date: 2017.06.27 MAXEON SOLAR PTE LTD

AI summary

Solar cell interconnects with multiple current paths. A solar cell interconnect may include a plurality of in-plane slits arranged in several rows. The in-plane slits may be spaced to provide strain relief without unduly increasing the electrical path resistance through the solar cell interconnect. The in-plane slits may be staggered, for example.