Jet Dispensing Module for Solar Panel Busbar Alignment
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Solution Overview
Problem
The manual manufacturing of solar panels is time-consuming and error-prone, making it costly to produce them in high volumes, particularly due to the difficulty in achieving precise alignment of strips for cascaded connections in solar panel manufacturing.
Innovation Solution
An automated system that includes a cartridge for holding conductive paste, a jet-dispensing module, and a robotic arm to precisely dispense conductive paste onto busbars of photovoltaic structures, ensuring accurate alignment and bonding between strips for cascaded connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual manufacturing methods are used for solar panels, then flexibility and adaptability are maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical alignment and paste application with an automated jet dispensing system. The jet dispensing module uses non-contact material ejection to apply conductive paste precisely onto busbars, eliminating the need for manual mechanical operations while maintaining high precision and enabling mass production of solar panels.
2Manufacturing precision
If manual alignment of strips is performed, then adaptability to variations is possible, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent employs vision systems and automated control mechanisms to achieve precise alignment of photovoltaic strips. The jet dispensing module is controlled by automated systems that ensure accurate positioning of conductive paste application, achieving high manufacturing precision without requiring complex manual adjustment mechanisms.
Solution Approach 2:
The patent uses vision systems to create optical copies or images of the busbar positions and strip locations. This allows the automated system to detect and compensate for position variations, achieving high alignment precision by referencing the visual information rather than relying on complex mechanical positioning systems.
3Manufacturing precision
If manual paste application is used, then equipment complexity is reduced, but manufacturing precision and consistency worsen
Solution Approach 1:
The patent replaces manual paste application with a jet dispensing module that uses non-contact material ejection. This automated system ensures consistent and precise conductive paste application onto busbars, eliminating variability associated with manual operations while the modular jet dispensing design keeps the added complexity manageable.
4Productivity
If automated manufacturing systems are implemented, then productivity increases, but initial device complexity and investment requirements worsen
Solution Approach 1:
The patent implements an automated manufacturing system featuring a jet dispensing module for non-contact conductive paste application, robotic arms for strip positioning, and vision systems for alignment. This comprehensive automation enables high-volume mass production of solar panels with consistent quality, justifying the increased device complexity through significant productivity gains and reduced per-unit costs at scale.
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 system enables high-precision, high-throughput dispensing of conductive paste, facilitating efficient cascaded connections and reducing production costs by automating the process, thereby addressing the challenges of manual alignment and increasing manufacturing efficiency.
Implementation Method 1
the jet-dispensing module can be configured to propel droplets of conductive paste onto the busbars
Data Source
AI summary
One embodiment of the invention provides an apparatus for dispensing conductive paste on photovoltaic structures during manufacturing of a solar panel. The apparatus includes a cartridge for holding the conductive paste, a jet-dispensing module coupled to the cartridge, and a robotic arm coupled to the jet-dispensing module. The jet-dispensing module is configured to dispense a predetermined amount of the conductive paste on busbars of a respective photovoltaic structure in a non-contact manner, and the robotic arm is configured to adjust a position of the jet-dispensing module, thereby facilitating alignments between the jet-dispensing module and the busbars of the photovoltaic structure.