Back-Contact PV Panel Assembly with Integrated ECA Printing
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Solution Overview
Problem
Existing assembly methods for photovoltaic panels with back-contact solar cells face challenges such as lengthy and error-prone conductive material laying, difficulty in handling and aligning cells with contacts upwards, and high costs due to complex equipment and waste issues, particularly with drop-by-drop dispensing and silkscreen printing processes.
Innovation Solution
A method that combines silkscreen printing of conductive adhesive (ECA) directly on the contacts of cells with simultaneous loading and pre-fixing, utilizing a macro-phase with coordinated sub-phases for oriented loading, printing, control, overturning, transport, and pre-fixing, integrated in a compact automated workstation, eliminating the need for separate dispensing and pre-fixing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drop-by-drop dispensing or silkscreen printing is used for conductive material laying, then manufacturing precision can be improved, but device complexity and production time increase significantly
Solution Approach 1:
The patent combines the conductive material laying operation with the cell loading operation into a single integrated process. The conductive adhesive is applied to the backsheet at contact points, and cells are loaded simultaneously in one motion, eliminating the need for separate dispensing equipment and reducing device complexity while maintaining precision through coordinated robotic execution
Solution Approach 2:
The conductive adhesive is pre-applied to the backsheet at the exact contact points before cell loading. This preliminary action ensures precise material placement without requiring complex dispensing equipment during the loading phase, as the adhesive is already positioned to receive the cells
2Manufacturing precision
If separate stations are used for conductive material laying and cell loading, then manufacturing precision can be maintained, but productivity decreases due to increased production time
Solution Approach 1:
The patent merges the conductive material laying station and cell loading station into a single combined operation. The robotic system performs both functions simultaneously - applying adhesive and loading cells in one coordinated motion sequence, thereby eliminating the time required to transfer the panel between separate stations while maintaining positioning precision through integrated control
Solution Approach 2:
The robotic arm performs continuous useful action by applying conductive adhesive and loading cells in an uninterrupted sequence. The system transitions smoothly between adhesive application and cell placement without idle transfer time, maximizing productivity while maintaining precision through coordinated motion control
3Manufacturing precision
If complex equipment is used for conductive material laying, then manufacturing precision improves, but loss of substance increases due to material waste
Solution Approach 1:
The conductive adhesive is pre-applied in precise amounts to predetermined contact points on the backsheet before cell loading. This preliminary, controlled application minimizes material waste by ensuring adhesive is only placed where needed, eliminating excess material that would require complex cleanup or rework operations
Solution Approach 2:
The system uses the cell loading process itself to achieve precise material placement. As cells are loaded onto the adhesive-covered contact points, the adhesive is automatically transferred and positioned with high precision, eliminating the need for separate precision dispensing equipment and reducing overall material waste
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 simplifies and accelerates the assembly process, reduces waste, enhances precision, and lowers costs by integrating printing and loading operations, allowing for faster and more reliable production of both conductive backsheet and glass-glass panels with reduced plant complexity and increased scalability.
Implementation Method 1
a second sub-phase (11b) of silkscreen printing of ECA on the contacts
Implementation Method 2
pre-fixing it in its final position
Data Source
AI summary
Assembly method of a photovoltaic panel with back-contact solar cells of crystalline silicon, which provides to print ECA adhesive directly on the contacts of the cells and to immediately load and pre-fix the printed cells. The method includes a macro-phase including operating sub-phases, simultaneous and coordinated with respect to each other: a first sub-phase of oriented loading of the cells with the contacts facing upwards on a mobile tray, a second sub-phase of silkscreen printing of ECA on the contacts, a third sub-phase of control of the laying carried out and of optional re-positioning of the screen, a fourth sub-phase of overturning of the printed cells, a fifth sub-phase of oriented transport of a string of cells up to positioning, a sixth sub-phase of pre-fixing. An automatic assembly plant is also disclosed having a combined station that allows for execution of the macro-phase.