Flexible Transport Foil for Thin Substrate Handling
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Solution Overview
Problem
Existing methods for transporting thin, flexible substrates in the photovoltaic industry are prone to damage and are costly, particularly due to the use of vacuum grippers and temporary carrier substrates, which are not economically viable for high-throughput processing.
Innovation Solution
A flexible transport foil/film system is developed, allowing for the safe and cost-effective transportation of thin substrates by using a soft, conductive, and woundable carrier with prefabricated substrates, featuring a flexible cement for secure attachment and easy detachment, and a design that prevents electrostatic charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum grippers are used to transport thin substrates, then substrates can be held securely, but substrates are damaged or broken and warpage occurs on suction holes
Solution Approach 1:
A transfer foil is introduced as an intermediary carrier between the vacuum gripper and the thin substrate. The foil is temporarily bonded to the substrate backside, allowing the vacuum gripper to hold the foil rather than the substrate directly, thereby preventing direct contact and damage to the substrate while maintaining secure transport.
Solution Approach 2:
The invention uses a flexible transfer foil as a protective intermediary layer. This thin film covers the substrate during transport, providing mechanical protection and electrical insulation while allowing the substrate to be handled through the foil's flexible carrier system.
2Reliability
If carrier substrates are used to support thin substrates, then substrates can be safely transported, but production costs increase significantly
Solution Approach 1:
The invention replaces expensive carrier substrates with a cost-effective transfer foil system. The foil can be temporarily bonded to the substrate using inexpensive adhesive layers and is designed to be easily separated and reused, significantly reducing the cost per transport cycle while maintaining substrate safety.
Solution Approach 2:
The transfer foil serves as a flexible, lightweight carrier that is much cheaper than rigid carrier substrates. Its flexibility allows it to conform to substrate shapes and be easily handled, while its thin film structure reduces material costs compared to using full carrier substrates.
3Ease of operation
If thin substrates are transported without support, then handling is simple, but substrates are damaged or broken during transport
Solution Approach 1:
The transfer foil acts as a protective intermediary that enables simple handling without direct substrate contact. The foil can be easily gripped and manipulated while the substrate remains protected underneath, allowing simple handling operations to be performed without compromising substrate integrity.
Solution Approach 2:
The transfer foil provides beforehand cushioning and protection for the substrate during handling operations. By bonding the foil to the substrate backside in advance, a protective layer is created that cushions the substrate against mechanical stresses during transport and manipulation.
4Productivity
If substrates are transported prefabricated on transport foil, then continuous processing is enabled, but the system becomes more complex
Solution Approach 1:
The transfer foil system enables continuous processing by allowing substrates to be transported prefabricated on the foil from one process module to the next without interruption. The foil acts as a continuous carrier that maintains substrate positioning and protection throughout the entire processing sequence, eliminating downtime for substrate handling and transfer.
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 enables the safe, efficient, and cost-effective transportation of thin substrates with minimal damage, supporting continuous processing and reducing material costs by using a flexible, wound, and conductive transport foil/film system that prevents scratches and ensures precise positioning.
Implementation Method 1
The substrates are temporarily fixed by an especially flexible cement, especially wound prefabricated onto a transport roll
Implementation Method 2
a design that prevents electrostatic charging
Data Source
AI summary
This invention relates to a transport foil/film as well as a transport system for holding and transport of at least one thin flexible substrate and a corresponding method and a use of a flexible transport foil/film for holding and for transport of at least one thin, flexible substrate, the substrates being able to be fixed or being fixed at least temporarily on the transport foil/film and the transport foil/film being drivable by driving means for transport of the substrates.