Staggered Solar Cell Connection Stations for PV Reliability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional photovoltaic cell manufacturing processes result in hidden cracks and loose connections due to uniform glue spot positioning, leading to shadow issues and reliability failures in EL tests, affecting module power and degradation.

Innovation Solution

A cell sheet design with staggered front and back connection stations and portions on the cell sheet, ensuring effective alignment and contact of metal interconnection strips with adhesive members, preventing loose connections and hidden cracks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glue spots are printed in a flush array with corresponding positions on front and back sides, then the manufacturing process is simple, but hidden cracks occur in the cell sheet during curing and pressing

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcell sheet integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies asymmetry by offsetting the positions of glue spots on the front side relative to those on the back side. Specifically, the glue spots on the front side are positioned at different locations compared to the corresponding glue spots on the back side, creating an asymmetric arrangement that prevents stress concentration and hidden cracks during the curing and pressing processes while maintaining manufacturing simplicity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent implements local quality by varying the glue spot positions at different locations on the cell sheet. Each connection station has specifically designed offset patterns between front and back glue spots, allowing localized optimization of stress distribution and connection quality without requiring complete redesign of the entire manufacturing process

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If glue spots have different heights and uneven down force during pressing, then the pressing process is simple, but fingers cannot effectively contact metal interconnection strips leading to loose connection

Engineering Contradiction:

Improvepressing process simplicityVSAvoidconnection integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by designing specific offset patterns for glue spots at different connection stations. Each connection station has tailored offset distances between front and back glue spots, ensuring that fingers make effective contact with metal interconnection strips at each location while maintaining overall process simplicity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements parameter changes by varying the offset distances between front and back glue spots at different connection stations. The offset distance is specifically designed to be within 0.5mm to 2.0mm, optimizing the contact between fingers and metal interconnection strips while accounting for different pressing forces and glue heights at various locations

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If glue spots are positioned in a flush array, then the design is simple, but shadow problems appear in EL test affecting module power

Engineering Contradiction:

Improvedesign complexityVSAvoidmodule power

Core Design Contradiction:

Device complexityVSPower

Solution Approach 1:

The patent applies asymmetry by offsetting glue spot positions between front and back sides, which eliminates the shadow problems that occur with flush array designs. This asymmetric arrangement prevents light reflection issues in EL tests while maintaining relatively simple design and manufacturing processes

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent implements local quality by optimizing glue spot positions at specific connection stations to eliminate shadows in critical areas. The offset patterns are designed to prevent shadow formation in EL tests while maintaining overall design simplicity and manufacturing feasibility

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4646064A1Battery cell, solar cell, and photovoltaic module

Publication Date: 2025.11.05 TONGWEI SOLAR ENERGY (CHENGDU) CO LID

Figure 1~3

AI summary

A battery cell, a solar cell, and a photovoltaic module. The front surface of the battery cell is provided with a plurality of front surface connecting stations distributed at intervals in a first direction, each front surface connecting station is provided with a plurality of first connecting parts distributed at intervals in a second direction, the back surface of the battery cell is provided with a plurality of back surface connecting stations distributed at intervals in the first direction, each back surface connecting station is provided with a plurality of second connecting parts distributed at intervals in the second direction, the plurality of first connecting parts of every two adjacent front surface connecting stations are distributed in a staggered manner, and/or the plurality of second connecting parts of every two adjacent back surface connecting stations are distributed in a staggered manner. The battery can reduce the reliability failure risk of the photovoltaic module.