Zoned Polymer Conductor Sheets for Solar Cell Interconnection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current solar cell production methods are inefficient and economically challenging due to the need for soldering individual electrical conductors or grids onto current-generating elements, which can be cumbersome and less effective in achieving stable electrical connections.
Innovation Solution
A polymer conductor sheet with zones of varying degrees of polymerization and crosslinking, allowing for a ductile and adhesive zone to securely fix elongated conductors, while a more stable zone provides mechanical strength and a third zone facilitates adhesion to external surfaces, enabling efficient and economic solar cell production by allowing for laminating and interconnecting solar cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If soldering individual electrical conductors or grids is used to achieve electrical connections, then electrical connectivity is established, but the production process becomes cumbersome and less efficient
Solution Approach 1:
The patent combines the electrical conductor and the polymer sheet into a single integrated component. The conductor is embedded within the polymer matrix during one-step coextrusion, eliminating the need for separate soldering operations and subsequent assembly steps. This merging of components directly addresses the productivity and ease of manufacture contradiction by streamlining the manufacturing process.
Solution Approach 2:
The electrical conductor is pre-positioned and secured within the polymer sheet during the extrusion process itself, before the solar cell assembly takes place. This preliminary action of embedding the conductor eliminates the need for later soldering operations, thereby improving production efficiency and reducing manufacturing complexity.
2Strength
If a homogenous polymer sheet is used, then material consistency is maintained, but the ability to provide both ductility for conductor fixation and mechanical strength is compromised
Solution Approach 1:
The patent creates zones with different degrees of crosslinking within the polymer sheet. The first zone has lower crosslinking density providing ductility and adhesion for conductor embedding, while the second zone has higher crosslinking density providing mechanical strength and stability. This local variation in material properties resolves the contradiction between strength and functional versatility.
Solution Approach 2:
The polymer sheet functions as a composite material system where regions with different crosslinking densities are integrated within a single homogeneous base material. This composite structure allows different zones to provide different functions (ductility vs. strength) while maintaining overall material consistency, thereby achieving both mechanical strength and functional versatility.
3Adaptability or versatility
If zone-specific polymerization is applied to create different degrees of crosslinking, then functional zones are created, but the processing complexity increases
Solution Approach 1:
The patent divides the polymer sheet into distinct zones during the extrusion process itself, with each zone having a predetermined crosslinking density. This segmentation is achieved through controlled coextrusion techniques where different polymer compositions are deposited in specific patterns. By segmenting the material distribution during manufacturing rather than requiring post-processing modifications, the patent achieves zone-specific functionality while managing processing complexity.
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
This approach enables efficient and cost-effective production of solar cells by providing stable and secure electrical connections through ductile and adhesive properties, improving mechanical strength and adhesion, thus enhancing the overall efficiency and reliability of solar cell modules.
Implementation Method 1
U.S. Pat. No. 6,586,271 B1 describes homogenously polymerized materials with high thermal creep resistance manufactured by irradiation-induced polymerization. The zones of the polymer sheet for use in the present invention are not the result of a step-wise assembly of different and/or separate layers but are individual zones encompassed within the same polymer matrix sheet, which zones differ in their degree of polymerization and or crosslinking.
Data Source
AI summary
The present invention relates to polymer conductor sheets comprising zones featuring different degrees of polymerization and/or crosslinking within the same polymer sheet, wherein the zones differ, for example, in mechanical stability, ductility and/or (thermo)adhesiveness. The present invention also teaches devices comprising these zoned polymer conductor sheets such as solar cell strings, matrices and modules, uses thereof and methods for producing these.