High-flatness battery piece bearing device

Abstract

The invention discloses a high-flatness battery piece bearing device, a bearing carrier plate mechanism comprises a battery piece bearing carrier plate tray and a frame, the frame supports the battery piece bearing carrier plate tray, the frame comprises a plurality of supporting cross beams which are transversely arranged and reinforcing ribs which are longitudinally distributed in a penetrating manner, and at least one part of the supporting cross beams is preset to be of a pre-arch structure; the top faces of the supporting cross beams are in a non-horizontal type under the condition that the supporting cross beams are not loaded, the pre-arch heights of the supporting cross beams are different, and the pre-arch heights of the supporting cross beams are optimized according to the specific positions of the supporting cross beams in the frame, the difference of local loads borne by the supporting cross beams and the interaction of components. According to the invention, the size design and the array arrangement of the groove units of the tray are optimized, and the pre-arch design of the cross beam is optimized based on the specific position in the frame, the difference of borne local loads and the interaction of components, so that the load deformation is effectively compensated, the high planeness can be kept under the working condition of a plurality of fragmented battery pieces, and the coating uniformity is improved.

Description

Technical Field

[0001] This invention belongs to the field of battery cell carrying and transportation technology in vacuum coating, and specifically relates to a high-flatness battery cell carrying device. Background Technology

[0002] In the vacuum coating process of photovoltaic cells, to achieve the transport and deposition of functional thin films, the cells need to be precisely positioned and transported in a vacuum chamber using a dedicated carrier device. The structural stability and flatness of the carrier directly determine the spatial orientation of the cell during the coating process, thus significantly affecting the film thickness distribution, refractive index uniformity, and interface characteristics. Therefore, the flatness of the cell carrier device is particularly critical in the vacuum coating process. However, existing cell carrier devices suffer from problems such as local warping, unevenness, and uneven gaps between the silicon wafer and the substrate, which in turn cause uneven film thickness distribution and deposition rate fluctuations, affecting the photoelectric performance and reliability of the final module. Existing large-size carriers (2750mm*2750mm) typically have a flatness of over 1.5mm under full load conditions, while 2150mm*2300mm carriers also have a flatness of over 1mm. Therefore, there is an urgent need to develop a cell carrier structure that combines high flatness retention, stability, and mass production applicability to meet the stringent requirements of high-efficiency photovoltaic devices for coating uniformity and yield. Improving the flatness of the carrier ensures that the silicon wafer maintains a consistent working distance within the vacuum chamber, significantly enhancing the uniformity of the coating and thus further guaranteeing the high-efficiency output and long-term stable operation of the module.

[0003] Meanwhile, with the continuous iteration of photovoltaic technology, reducing module costs and improving power generation efficiency have become common goals across the industry. By subdividing a single cell into multiple smaller units and then repackaging them into modules, not only can output power be significantly increased, but also higher reliability can be achieved. This process is collectively known as "cell slicing technology." Looking at the development history of photovoltaic modules, the earliest approach used single-cell modules, followed by the second-generation "half-cell" era, where cells were cut in half using a bisection method. Half-cell modules achieved large-scale commercialization around 2018, and now hold over 90% of the global market share. However, with the widespread adoption of large-size silicon wafers such as 210mm, the half-cell structure struggles to continue releasing its power potential due to increased series resistance. Therefore, multi-slicing technology is considered the next mainstream approach. Research shows that multi-slicing technology, while maintaining process controllability, can significantly reduce resistance losses and achieve higher conversion efficiency, making it a recognized future upgrade direction in the industry. Therefore, multi-cell batteries face unique process challenges in the vacuum coating process, and there is an urgent need to develop dedicated carriers. Existing carriers lack compatibility. Most existing traditional carriers serve whole-cell and half-cell technologies, but the slot design of traditional whole-cell and half-cell carriers cannot be adapted to the three-cell layout, making it difficult to meet the future development direction of the industry.

[0004] Therefore, from the perspectives of process and device performance and development needs, high-planarity multi-cell solar cell carriers can improve the uniformity of solar cell coating and meet the new trends in future development. Summary of the Invention

[0005] Purpose of the invention: The purpose of this invention is to overcome the shortcomings of the prior art and provide a high-flatness battery cell support device.

[0006] Technical Solution: A carrier plate mechanism is provided, which includes a battery cell carrier plate tray and a frame. The battery cell carrier plate tray is used to place multiple battery cells for coating. The frame supports the battery cell carrier plate tray. The frame includes multiple horizontally arranged support beams and longitudinally interspersed reinforcing ribs. At least a portion of the support beams are pre-arched, and the pre-arch height of each pre-arch structure is different. The pre-arch structure of the support beam means that the height difference between the highest point and the lowest point of the top surface of the support beam is greater than 0 mm. Under no load, the top surface of the support beam is non-horizontal. The pre-arch height of each support beam is different and is optimized based on its specific position in the frame, the difference in local load it bears, and the interaction of the components.

[0007] A further improvement of the present invention is that the pre-arched structure of the supporting beam includes, but is not limited to, an upward bend in the form of an arc, a polynomial function curve, or multiple straight lines.

[0008] A further improvement of the present invention is that the pre-camber height of each supporting beam is different, and is optimized based on its specific position in the frame, the difference in the local load it bears, and the interaction of the components. The methods include, but are not limited to, finite element simulation and actual experimental optimization.

[0009] A further improvement of the present invention is that the cell carrier tray has multiple grooved cell carrier units, each cell carrier unit being used to carry N cells of size that are one-Nth of a conventional cell.

[0010] A further improvement of the present invention is that the size of a single cell carrier unit is suitable for cells using multi-segment technology or cells of approximately multi-segment size, and the cell carrier units are arranged in an array.

[0011] A further improvement of the present invention is that the size of the carrier plate mechanism is greater than or equal to 2015mm×2015mm, the thickness of the battery cell carrier plate tray is 1-2mm, and the flatness difference of the carrier plate mechanism remains stable in the static state and after the transmission state.

[0012] A further improvement of the present invention is that the cross-sectional width of each supporting beam is in the range of 2 to 10 mm, the height is in the range of 2 to 15 mm, and the total number of supporting beams is limited to no less than 5, so as to ensure the stability of structural rigidity and overall flatness.

[0013] A further improvement of the present invention is that the main material of the load-bearing plate mechanism is selected from, but is not limited to, any one or a combination of the following high-performance materials: carbon / carbon composite materials, stainless steel, aluminum alloy, titanium alloy, polyether ether ketone, or polyvinylidene fluoride, to meet the requirements of strength, rigidity, corrosion resistance and thermal stability under different working environments.

[0014] Compared with the prior art, the present invention achieves at least the following beneficial effects: This invention proposes a large-size carrier plate with a high flatness design. Through structural innovation, material selection, and process compatibility, this device achieves high flatness maintenance and improved film uniformity during vacuum coating. The optimized tray groove unit size design and array arrangement enable the improved carrier plate to support standard multi-cell battery cells. This design provides a guarantee for the support of multi-cell battery cells, ensuring product quality and consistency. At the same time, the optimized beam structure provides better flatness, effectively compensating for load deformation. Using materials with different strengths, the flatness difference can be within 1mm under full load conditions, thus ensuring coating uniformity. Attached Figure Description

[0015] Figure 1 A schematic diagram of a crossbeam pre-cambered by 8mm; Figure 2 (a) is a schematic diagram of a tray for a bi-cell solar cell carrier plate, wherein the tray shows the distribution layout of the groove carrier units for placing silicon wafers on the solar cell carrier plate. Figure 2 (b) is a schematic diagram of the bottom frame of the two-cell battery cell. The horizontal direction is a support beam with a pre-arched shape, and the vertical direction is a reinforcing rib that passes through the beam and provides support. Figure 3 (a) is a schematic diagram of a tray for a three-cell solar cell carrier plate, wherein the tray shows the distribution layout of the groove carrier units for placing silicon wafers on the solar cell carrier plate. Figure 3 (b) is a schematic diagram of the bottom frame of the three-cell battery. The horizontal direction is a support beam with a pre-arched shape, and the vertical direction is a reinforcing rib that passes through the beam and provides support. Figure 4 (a) is a detailed view of the bi-cell battery cell carrier unit; Figure 4 (b) is a detailed view of the three-cell battery cell carrier unit; Figure 5 This is a schematic diagram of the carrier plate model; Figure 6(a) is the pre-camber height of the load-bearing plates for the two-cell and three-cell solar cells that are not individually designed for each crossbeam; Figure 6 (b) The pre-camber height of each beam is optimized based on its specific position in the frame, the differences in local loads it bears, and the interaction of components; Figure 6 (c) Comparison of two different pre-arch heights; Figure 7 (a) is a comparison diagram of the flatness of the carrier plate in a static state; Figure 7 (b) is a comparison diagram of the flatness of the carrier plate after dynamic transmission conditions.

[0016] Explanation of reference numerals in the attached figures: 1-Battery cell support tray; 2-Battery cell support unit; 3-Support beam; 4-Reinforcing rib. Detailed Implementation

[0017] Various exemplary embodiments of the present invention will now be described in detail. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0018] Techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and apparatus should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0019] See Figure 1-7 (b) A high-flatness solar cell carrier device for photovoltaic multi-cell technology, comprising a carrier plate mechanism, including a solar cell carrier plate tray 1 and a frame. The frame includes support beams 3 with different pre-arch heights. This design improves the flatness of the carrier plate and enhances the coating quality. The size of the solar cells supported for coating is one-third that of conventional solar cells. The carrier plate tray 1 has a solar cell carrying unit 2 for placing silicon wafers. The flatness difference of the carrier plate mechanism under full load is within 1 mm. Maintaining a flatness difference within 1 mm, the carrier plate mechanism can be used to support solar cells of different weights, with a capacity of 208 to 488 solar cells. The carrier plate mechanism is made of carbon / carbon composite material.

[0020] The flatness of common PECVD cell carrier plates is typically greater than 1.5mm. Poor flatness can lead to uneven coating and affect cell quality. Furthermore, cell carrier plates are often used for two-cell cells. Two-cell carrier plates are less efficient than multi-cell carrier plates. Therefore, in the design of multi-cell carrier plates, the tray size is designed to suit the size of multi-cell cells to match the trend of the photovoltaic industry upgrading to multi-cell technology. Additionally, based on simulation calculations, different pre-camber heights are designed for the crossbeams supporting the tray to achieve a flatness control within 1mm after supporting the cells.

[0021] Subsequent embodiments focus on the three-cell solar cell support plate, specifically studying the flatness of the crossbeams designed for different methods in the two-cell and three-cell solar cell support units. The two-cell and three-cell solar cell support plates have the same dimensions, and their material performance parameters are also basically the same.

[0022] Example 1 The bi-cell solar cell support plate measures 2750mm x 2750mm. It features 27 supporting beams and 26 reinforcing ribs, all of which pass through the beams to enhance their strength. The supporting beams are pre-cambered, with the pre-camber height as shown. Figure 6 As shown in (a), the structure of the carrier plate mechanism is shown in 1(b). The thickness of the solar cell carrier plate tray 1 is 1mm, used to carry 100% silicon wafers, and its weight is 1.4kg. There are 12 columns in the guide rail direction and 24 columns in the valve direction. The carrier plate can hold 288 wafers. The arrangement of the solar cell carrier units is as follows. Figure 2 As shown in (a), the size of a single solar cell carrier unit is 212mm × 106mm, as follows. Figure 3 As shown in (a), the size of a single silicon wafer used for testing is 210mm × 105mm. After the frame is assembled, the tray and frame are locked together, and then the silicon wafer is placed in each cell carrier unit.

[0023] Test 1: After assembly, a guide rail was placed on the infrared flatness testing platform. The guide rail side frame of the battery cell carrier plate was placed on the guide rail to test the stress on the battery cell carrier plate during static actual use. The midpoint of the spacing between each battery cell carrier unit on the tray of the carrier plate was used as the measurement point, i.e., 14 columns were taken on the guide rail side and 26 columns on the valve side, for a total of 364 measurement points. The infrared flatness testing platform was used to measure and record the results. The maximum and minimum values ​​of the 364 recorded measurement points were selected, and the difference between the maximum and minimum values ​​was taken as the flatness data. The results showed that the flatness of the pre-arched two-section battery cell carrier plate was 1.67 mm.

[0024] Test 2: After assembly, the cell carrier plate was placed on the guide rail of the transmission platform along the guide rail side. The flatness of the carrier plate was tested under dynamic transmission conditions at a transmission speed of 500 mm / s for 15 hours. Similarly, the midpoint of the spacing between each cell carrier unit on the carrier plate tray was used as the measurement point, i.e., 14 columns on the guide rail side and 26 columns on the valve side, for a total of 364 measurement points. Measurements were taken using an infrared flatness testing platform and recorded. The maximum and minimum values ​​of the 364 recorded measurement points were selected, and the difference between the maximum and minimum values ​​was taken as the flatness data. The results showed that the flatness of the pre-arched two-section cell carrier plate was 1.71 mm.

[0025] Example 2 The three-cell solar cell support plate measures 2750mm x 2750mm. It features 27 supporting beams and 26 reinforcing ribs, all of which pass through the supporting beams to enhance their support strength. The supporting beams are pre-cambered, with the pre-camber height as shown. Figure 6 As shown in (a), the frame structure is as follows: Figure 2 As shown in (b). The thickness of the solar cell carrier tray is 1mm, used to support silicon wafers, and its weight is 1.4kg. The carrier tray can hold 408 silicon wafers, as shown. Figure 2 As shown in (a), the size of a single silicon wafer unit is 212mm * 73mm, as... Figure 3 (b) shows the process. After the frame is assembled, the tray and frame are locked together, and then the silicon wafer is placed in each cell carrier.

[0026] Test 1: After assembly, a guide rail was placed on the infrared flatness testing platform. The guide rail side frame of the three-cell solar cell carrier plate was placed on the guide rail to test the stress on the solar cell carrier plate during static actual use. The midpoint of the spacing between each solar cell carrier unit on the tray of the carrier plate was used as the measurement point, i.e., 14 columns were taken on the guide rail side and 20 columns on the valve side, for a total of 280 measurement points. The infrared flatness testing platform was used for measurement. The maximum and minimum values ​​of the 280 recorded measurement points were selected, and the difference between the maximum and minimum values ​​was taken as the flatness of the carrier plate. Data results: The flatness of the three-cell solar cell carrier plate under this pre-arch is 1.62mm.

[0027] Test 2: After assembly, the battery cell carrier plate was placed on the guide rail of the transmission platform along the guide rail side. The flatness of the carrier plate was tested under dynamic transmission conditions at a transmission speed of 500 mm / s for 15 hours. Similarly, the midpoint of the spacing between each battery cell carrier unit on the carrier plate tray was used as a measurement point, i.e., 14 columns on the guide rail side and 20 columns on the valve side, for a total of 280 measurement points. Measurements were taken using an infrared flatness testing platform and recorded. The maximum and minimum values ​​of the 280 recorded measurement points were selected, and the difference between the maximum and minimum values ​​was taken as the flatness data. The flatness of the carrier plate after transmission of the pre-arched three-cell battery cells was determined to be 1.65 mm.

[0028] Example 3 The three-cell solar cell carrier plate measures 2750mm x 2750mm. It features 27 support beams and 26 reinforcing ribs, all of which pass through the support beams to enhance their strength. The tray is 1mm thick and supports 100% silicon wafers, weighing 1.4kg. The carrier plate can hold up to 408 silicon wafers. Figure 2 As shown in (a), the size of a single silicon wafer unit is 212mm * 73mm, as... Figure 3 As shown in (b). A 1:1 scale model of the carrier plate is used, and the schematic diagram is shown below. Figure 5 As shown. A load was applied to the top surface of the model's tray, and solid mechanics calculations were performed using finite element simulation to simulate the gravity and temperature under actual operating conditions of the carrier plate. The collapse of the carrier plate was obtained, and the center point of each crossbeam was extracted. The deformation of each crossbeam was obtained through data analysis. Based on the collapse of each crossbeam, a corresponding pre-camber was set for the crossbeams. The model with the pre-camber set was recalculated, and the results showed that the flatness decreased to within 0.1 mm. The pre-camber height is shown below. Figure 6 As shown in (b).

[0029]

[0030] The carbon / carbon material sheet is cut using wire cutting. The cut beams are then ground, drilled, cleaned, and assembled. After the frame is assembled, the tray and frame are locked together, and then silicon wafers are placed in each cell-bearing unit.

[0031] Test 1: After assembly, a guide rail was placed on the infrared flatness testing platform. The guide rail side frame of the three-cell solar cell carrier plate was placed on the guide rail to test the stress on the solar cell carrier plate during static actual use. Measurement points were taken at the midpoint of the spacing between each solar cell carrier unit on the carrier plate's tray, i.e., 14 columns on the guide rail side and 20 columns on the valve side, for a total of 280 measurement points. Measurements were taken using the infrared flatness testing platform. The results showed that the flatness of the three-cell solar cell carrier plate was 0.85mm. The loading of the three-cell solar cells was achieved by modifying the size of individual solar cell carrier units and optimizing the carrier unit arrangement. Figure 6 (b) The flatness of the carrier plate compared to Figure 6 (a) The flatness of the slab with the designed pre-arch height has been greatly improved, reducing the flatness of the slab to less than 1 mm.

[0032]

[0033] Test 2: After assembly, the battery cell carrier plate was placed on the guide rail of the transmission platform along the guide rail side. The flatness of the carrier plate was tested under dynamic transmission conditions at a transmission speed of 500 mm / s for 15 hours. The flatness of the three-cell battery cell carrier plate was 0.79 mm. 14 columns were taken on the guide rail side and 20 columns on the valve side, for a total of 280 measurement points. Measurements were taken and recorded using an infrared flatness testing platform. The difference between the maximum and minimum values ​​was selected as the flatness of the carrier plate. The flatness of the carrier plate under vibration transmission conditions achieved a flatness difference within 1 mm.

[0034]

[0035] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A high-flatness solar cell support device, characterized in that, A carrier plate mechanism is provided, which includes a battery cell carrier plate tray (1) and a frame. The battery cell carrier plate tray (1) is used to place multiple battery cells for coating. The frame supports the battery cell carrier plate tray (1). The frame includes multiple horizontally arranged support beams (3) and longitudinally interspersed reinforcing ribs (4). At least a portion of the support beams (3) are pre-arched, and the pre-arch height of each pre-arch structure is different. The pre-arch structure of the support beam (3) means that the height difference between the highest point and the lowest point of the top surface of the support beam (3) is greater than 0 mm. When not under load, the top surface of the support beam (3) is non-horizontal. The pre-arch height of each support beam (3) is different and is optimized based on its specific position in the frame, the difference in local load it bears, and the interaction of components.

2. The high flatness solar cell support device according to claim 1, characterized in that, The pre-arched structure of the supporting beam (3) includes, but is not limited to, upward bending in the form of an arc, a polynomial function curve, or multiple straight lines.

3. The high-flatness solar cell support device according to claim 1, characterized in that, The pre-arch height of each supporting beam (3) is different, and is optimized based on its specific position in the frame, the difference in local load it bears, and the interaction of components. The methods include, but are not limited to, finite element simulation and actual experimental optimization.

4. The high flatness solar cell support device according to claim 1, characterized in that, The battery cell carrier tray (1) has multiple grooved battery cell carrier units (2), each battery cell carrier unit (2) is used to carry N battery cells with a size of one-Nth of a conventional battery cell.

5. A high-flatness solar cell support device according to claim 4, characterized in that, The size of a single cell carrier unit (2) is suitable for a cell of multi-segment technology or a cell of approximately multi-segment size, and the cell carrier units (2) are arranged in an array.

6. The high flatness solar cell support device according to claim 1, characterized in that, The dimensions of the carrier plate mechanism are greater than or equal to 2015mm × 2015mm, the thickness of the battery cell carrier plate tray (1) is 1 to 2mm, and the flatness difference of the carrier plate mechanism remains stable in the static state and after the transmission state.

7. The high flatness solar cell support device according to claim 1, characterized in that, The cross-sectional width of each supporting beam (3) ranges from 2 to 10 mm, the height ranges from 2 to 15 mm, and the total number of supporting beams is limited to no less than 5, in order to ensure the stability of structural rigidity and overall flatness.

8. A high-flatness solar cell support device according to claim 1, characterized in that, The main material of the carrier plate mechanism is selected from any one or a combination of the following high-performance materials: carbon / carbon composite material, stainless steel, aluminum alloy, titanium alloy, polyether ether ketone (PEEK) or polyvinylidene fluoride (PVDF) to meet the requirements of strength, rigidity, corrosion resistance and thermal stability under different working environments.

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