Laser Edge Coating Removal via Optical Tracking
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Solution Overview
Problem
Existing methods for controlling the edge width of photovoltaic devices are expensive and require significant downtime due to the need for precise positioning, and they lack the ability to efficiently direct a laser beam to ablate coatings at the edge of substrates effectively.
Innovation Solution
A system that uses an edge-tracking instrument to locate the edge of a photovoltaic device, adjusting both the substrate and laser source positions to create contiguous non-coated sections, employing a pulsed laser beam with near-infrared frequency and XYZ galvanometer-controlled mirrors for precise scribing, and includes gas pressure and vacuum positioners for accurate focusing and ablation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional precision fixtures and XY positioning tables are used to control edge width, then positioning precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical positioning systems (precision fixtures and XY positioning tables) with an optical tracking system. A sensor detects the substrate edge position, and a controller automatically adjusts the laser beam position based on detected deviations, substituting mechanical precision with optical-mechanical integration.
Solution Approach 2:
The system performs self-adjustment by detecting edge position deviations and automatically correcting the laser beam position. The sensor-controller-laser system continuously monitors and self-corrects positioning errors without requiring external intervention or complex pre-positioning fixtures.
2Manufacturing precision
If traditional precision fixtures and XY positioning tables are used to control edge width, then positioning precision is improved, but production downtime increases due to maintenance requirements
Solution Approach 1:
The patent eliminates complex mechanical positioning systems that require frequent calibration and maintenance. The optical sensor and controller system has fewer moving parts and requires minimal maintenance, significantly reducing production downtime while maintaining positioning precision.
Solution Approach 2:
The system continuously self-adjusts during operation without requiring shutdowns for recalibration. The real-time feedback loop allows the system to maintain precision throughout production runs, eliminating downtime associated with traditional mechanical system maintenance.
3Ease of manufacture
If a fixed orientation laser beam at 0° angle of incidence is used, then laser alignment is simplified, but the ability to redirect the beam to track substrate edges is lost
Solution Approach 1:
The patent transforms the static, fixed-orientation laser system into a dynamic one. The laser beam orientation is continuously adjusted based on real-time edge position feedback, allowing the system to adapt to substrate variations while maintaining alignment through active control rather than fixed mechanical mounting.
Solution Approach 2:
The system uses sensor feedback to continuously monitor substrate edge position and automatically adjusts laser beam orientation accordingly. This closed-loop control allows the laser to track edges dynamically while maintaining precise alignment, combining the simplicity of fixed mounting with the versatility of active redirection.
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
Enables efficient and precise removal of coatings from the edges of photovoltaic devices, reducing downtime and costs by maintaining precise positioning tolerances and ensuring consistent non-conductive edge widths, thereby maximizing device output.
Implementation Method 1
employing a pulsed laser beam with near-infrared frequency and XYZ galvanometer-controlled mirrors for precise scribing
Implementation Method 2
ablating a coating at a position corresponding to the located edge
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A method for removing coating from a substrate may include: locating an edge of a substrate; directing a laser beam along a first path to a first position on a surface of the substrate proximate to an edge of the substrate at an angle of incidence suitable to redirect the laser beam along a second path, through the substrate, to a second position on a second surface of the substrate corresponding to the located edge of the substrate, where the second surface can include a coating; and ablating at least a portion of coating at the second position on the second surface of the substrate.