Welding Ribbon Depression for Photovoltaic Module Tension
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Solution Overview
Problem
Conventional welding ribbon components for solar cells have insufficient welding tension and are prone to cracking, especially in high-density packaging scenarios, due to limited contact area and excessive thickness of the welding coating, leading to false welding and desoldering issues.
Innovation Solution
A welding ribbon component with a first welding ribbon segment featuring a depression on its surface and a second segment with a plane welding surface, both coated with specific welding coatings, enhancing contact area and preventing cracking by containing molten aggregates within the depression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the welding coating is increased to ensure sufficient contact area, then the welding tension is improved, but the volume of foreign matter points increases and cracking of the battery piece is exacerbated
Solution Approach 1:
The welding ribbon component is divided into multiple segments (first welding ribbon segment, connecting segment, second welding ribbon segment) with different structural characteristics. The first segment features a depression structure that segments the molten coating material, preventing it from forming large aggregates that cause cracking, while still maintaining sufficient contact area for welding tension.
Solution Approach 2:
Different segments of the welding ribbon component have different local structures optimized for specific functions. The first welding ribbon segment has a depression structure for containing molten material, the connecting segment has a specific geometry for bridging, and the second segment has a plane structure for welding. This local differentiation allows the coating thickness to be optimized locally - thick enough for welding tension where needed, but controlled to prevent cracking where molten material accumulates.
2Strength
If the thickness of the welding coating is increased to improve welding tension, then the contact area is improved, but the one-time forming rate of photovoltaic module is reduced due to false welding and desoldering
Solution Approach 1:
The depression structure segments the welding coating into controlled regions, preventing uncontrolled aggregation of molten material. This segmentation ensures uniform distribution of the welding coating, providing consistent welding tension across the contact area and reducing variations that lead to false welding and desoldering, thereby improving one-time forming rate.
Solution Approach 2:
The depression structure is pre-formed on the welding ribbon component before the welding process. This preliminary structural preparation guides the flow and distribution of the welding coating material, ensuring it is properly positioned and contained before melting occurs. This prevents improper material distribution that would cause welding defects and reduces one-time forming rate.
3Device complexity
If a conventional round-wire-shaped welding ribbon component is used, then the device complexity is low, but the contact area with battery pieces is too small, leading to insufficient conductivity and welding tension
Solution Approach 1:
The welding ribbon component transitions from a simple round-wire shape to a multi-dimensional structure with segments and a depression. The depression creates a three-dimensional feature that increases the surface area available for contact with the battery piece without significantly increasing the overall complexity of the component. This dimensional enhancement provides sufficient contact area for improved conductivity and welding tension.
4Productivity
If the thickness of the welding coating is increased to achieve high-density packaging, then the welding tension is improved, but the probability of single-point stress on battery pieces increases causing hidden cracks
Solution Approach 1:
The depression structure segments the welding coating material, distributing it across multiple controlled regions rather than allowing it to concentrate at single points. This segmentation reduces the probability of single-point stress on battery pieces during high-density packaging, preventing hidden cracks while maintaining sufficient welding tension through increased overall contact area.
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
The solution increases contact area and welding tension, reduces desoldering, and allows for high-density packaging without cracking, while minimizing material use and cost.
Implementation Method 1
after a welding coating on the welding ribbon component is melted, it will gather at positions of silver paste points on the battery pieces to form molten aggregates
Data Source
AI summary
The present application provides a welding ribbon component and a preparation method therefor, and a photovoltaic module. The welding ribbon component includes: a first welding ribbon segment, a second welding ribbon segment, and a connecting segment, and the connecting segment is located between the first welding ribbon segment and the second welding ribbon segment. The first welding ribbon segment includes a first welding ribbon body, a surface of the first welding ribbon body being provided with a depression; and a first welding coating located at least on a surface of an inner wall of the depression. The welding ribbon component of the present application can increase the thickness of the welding coating to improve the welding tension, and can reasonably control the thickness to prevent cracking, while also achieving high-density packaging.