Adjustable Wet Etching Roller for Solar Cell Levelness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wet etching process for solar cell manufacturing faces issues with abnormal roller levelness due to wear and machining precision deviations, leading to uneven etching quality and increased costs.
Innovation Solution
A liquid-carrying roller with adjustable end shafts and wedges, allowing for real-time diameter adjustments to maintain horizontal placement and ensure consistent etching quality, utilizing PVDF or PTFE materials for durability and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the roller diameter is reduced due to wear, then the roller can be used longer, but the silicon wafer cannot move horizontally during transportation affecting etching quality
Solution Approach 1:
The roller diameter is made dynamically adjustable through a wedge mechanism. When the roller surface wears down, the wedges can be adjusted to increase the roller diameter, maintaining the horizontal transportation of silicon wafers and ensuring etching quality throughout the roller's service life.
Solution Approach 2:
The physical parameter of roller diameter is changed from fixed to variable. By adjusting the wedge position, the roller diameter can be increased to compensate for wear, thereby maintaining the required manufacturing precision for extended periods.
2Duration of action of stationary object
If the roller surface becomes uneven due to wear, then the roller continues to function, but water film slides into chemical solution causing abnormal concentration
Solution Approach 1:
The roller geometry is made dynamically adjustable to maintain a smooth surface profile. As the roller surface wears, the wedge adjustment mechanism restores the original diameter and surface uniformity, preventing water film instability and maintaining chemical solution concentration reliability.
3Ease of manufacture
If the bracket and roller machining precision deviates, then production costs are reduced, but roller levelness becomes abnormal affecting overall etching effect
Solution Approach 1:
Instead of requiring high initial machining precision, the design uses a simple wedge adjustment mechanism that allows post-manufacturing calibration. This enables low-cost manufacturing of components while maintaining high roller levelness through easy field adjustment.
Solution Approach 2:
The system provides its own levelness adjustment capability through the wedge mechanism, eliminating the need for expensive precision machining or external calibration services. The operator can self-adjust the roller levelness using the provided mechanism.
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 adjustable liquid-carrying roller reduces operating costs and maintains etching quality by allowing for real-time adjustments to compensate for wear and precision deviations, ensuring horizontal placement and consistent etching results.
Implementation Method 1
The end shafts at both ends of the liquid-carrying shaft are respectively provided with a wedge structure
Implementation Method 2
a liquid-carrying roller for wet etching, comprising a liquid-carrying shaft
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
The invention, which relates to a liquid-carrying roller for wet etching and a wet etching method, belongs to the technical field of solar cell manufacturing, and solves the problem of abnormal roller levelness in a process of manufacturing a solar cell in the prior art. The liquid-carrying roller for wet etching of the invention comprises a first end shaft, a second end shaft, and a liquid-carrying shaft, the first end shaft and the second end shaft being located at both ends of the liquid-carrying shaft, respectively, the first end shaft, the second end shaft and the liquid-carrying shaft being arranged concentrically, and the diameters of the first end shaft and the second end shaft being both adjustable. The diameters of the two end shafts of the liquid-carrying shaft of the invention may be adjusted, and when abnormal roller levelness is resulted in due to wear of the both ends of the liquid-carrying roller or machining precision of an etching tank, a horizontal state of the liquid-carrying roller on a bracket is ensured, which greatly reduces operating costs of a wet etching device while guaranteeing quality during solar cell etching.