Explosive Expansion Assembly for Micro PV Cell Spreading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and inefficiency of photovoltaic (PV) solar cell fabrication and assembly, particularly in spreading microscale PV cells from a dense 2D configuration on wafers to a more spread out layout for concentrated PV applications, where cells need to be separated by 3-10 mm, using current pick-and-place techniques which are time-consuming and expensive, especially for smaller cell sizes.
Innovation Solution
A method and apparatus utilizing an explosive or expansion assembly with guide wires and linkage bars to spread microscale PV cells in a massively parallel manner, positioning guide wires between cells in an orthogonal or non-orthogonal configuration to move cells apart in the x and y directions, allowing for 2D expansion from a contracted to a fully extended position of 3-10 mm, enabling efficient transfer to CPV modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pick-and-place techniques are used to spread microscale PV cells, then individual cell placement precision is achieved, but the process becomes time-consuming and expensive
Solution Approach 1:
The system divides the wafer into multiple quadrants and processes them simultaneously using distributed actuators. Each actuator handles a specific region, enabling parallel processing of multiple cell arrays at once, thus increasing productivity while maintaining precision through localized control
Solution Approach 2:
The invention replaces traditional mechanical pick-and-place systems with a magnetic field-based actuation system. Magnetic actuators manipulate cell arrays directly on the wafer surface through magnetic forces, eliminating the need for physical pickup and placement mechanisms, thereby significantly increasing spreading speed while maintaining placement precision
2Manufacturing precision
If pick-and-place techniques are used to spread microscale PV cells, then individual cell placement is achieved, but the cost increases significantly
Solution Approach 1:
The invention replaces expensive mechanical pick-and-place equipment with a magnetic field-based system that uses electromagnetic actuators. This substitution dramatically reduces equipment cost and operational expense while maintaining the ability to precisely position cells through magnetic field control
Solution Approach 2:
The system changes the control parameter from mechanical position to magnetic field strength and distribution. By varying magnetic field parameters, the system can precisely control cell positions without requiring complex mechanical positioning mechanisms, thereby reducing manufacturing cost while maintaining precision
3Adaptability or versatility
If microscale PV cells are spread out to 3-10 mm spacing for CPV applications, then light concentration capability is improved, but the complexity of the spreading system increases
Solution Approach 1:
The system divides the wafer into multiple quadrants and processes them simultaneously using distributed actuators. Each actuator handles a specific region, enabling parallel processing of multiple cell arrays at once, thus increasing spreading speed while maintaining precision through localized control
Solution Approach 2:
The magnetic actuation system serves multiple functions: it can spread cells to various spacing configurations (3-10 mm), accommodate different cell sizes and shapes, and adapt to different CPV module designs. This universal approach simplifies the overall system by replacing multiple specialized mechanical systems with a single versatile magnetic field-based platform
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 solution significantly reduces the time and cost associated with spreading microscale PV cells, enabling efficient assembly into CPV modules while maintaining precise control over cell spacing, thus addressing the competitiveness of photovoltaic systems with fossil-fuel generated electricity.
Implementation Method 1
an explosive or expansion assembly that utilizes the approximately 10 micron gap between each microscale PV cell and positions a guide wire or ribbon within this gap
Implementation Method 2
The linkage bars are then rotated in a coordinated manner such that the guide wires that hug the perimeter of each PV cell or other microelectronic device move each cell or device in both the x and y direction to a designated position
Implementation Method 3
The linkage members are, for example, microscale truss members that can expand to spread the pads apart in both the x and y directions and, in turn, spread cells positioned thereon
Data Source
AI summary
An apparatus, method, and system, the apparatus including a receiving member dimensioned to receive an array of microelectronic devices; and a linkage member coupled to the receiving member, the linkage member configured to move the receiving member in at least two dimensions so as to modify a spacing between the electronic devices within the array of microelectronic devices received by the receiving member. The method including coupling an array of microelectronic devices to an expansion assembly; and expanding the expansion assembly so as to expand the array of microelectronic devices in at least two directions within a single plane. The system including a support member; an expansion assembly coupled to the support member, the expansion assembly having a plurality of receiving members configured to move in at least two dimensions within a single plane; and a plurality of microelectronic devices coupled to each of the plurality of receiving members.