Magnetic Electroplating Frame for Solar Cell Alignment

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Solution Overview

Problem

The electroplating process for solar cells is manually intensive and time-consuming due to the need for individual placement and alignment of small plating electrodes, which can lead to breakages and inefficiencies in solar cell production.

Innovation Solution

An electroplating frame with magnetically coupled upper and lower frames, featuring alignment features and support structures, is used to securely hold and precisely align solar cells, allowing for automated handling and electroplating, reducing manual intervention and handling-related issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual placement and alignment of small plating electrodes is used, then precise alignment can be achieved, but the process becomes manually intensive and time-consuming

Engineering Contradiction:

Improvealignment precisionVSAvoidproduction throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The solar cell processing system is divided into multiple stations (first station for initial plating, second station for final plating) that perform different functions. This segmentation allows automated handling at each station while maintaining precise alignment through dedicated alignment features at each station, resolving the contradiction between manual precision and automated throughput.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A frame structure with alignment features serves as an intermediary between the automated handling system and the solar cell. The alignment features on the frame provide precise positioning references that guide automated placement of plating electrodes, enabling both automation and precision without requiring manual intervention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If manual handling of solar cells is used, then precise placement can be achieved, but handling-related breakages increase

Engineering Contradiction:

Improveplacement precisionVSAvoidcell integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The frame structure with integrated alignment features enables the solar cell to self-align during automated handling. The alignment features work with the automated handling system to provide precise positioning without requiring complex manual manipulation, thereby reducing handling-induced stress and breakage while maintaining placement precision.

Inventive Principle:

Principle #25Self-service

3Reliability

If multiple layers of low temperature paste are applied, then adequate conductivity can be achieved, but process complexity and cost increase

Engineering Contradiction:

Improveelectrical conductivityVSAvoidlayering process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical layering process with an electroplating process. Instead of manually or mechanically applying multiple layers of paste, the electroplating process deposits conductive material in a single controlled step, achieving adequate conductivity without the complexity of multiple application layers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If copper electroplating is used instead of silver paste, then cost is reduced, but adhesion to silicon deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidadhesion strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The system performs preliminary plating at the first station to create an initial copper layer with adequate adhesion to the silicon surface. This preliminary action establishes a foundation that maintains adhesion reliability while enabling cost-effective copper electroplating to proceed without requiring expensive silver paste.

Inventive Principle:

Principle #10Preliminary action

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 electroplating frame enhances the efficiency of the solar cell electroplating process by enabling automated handling and precise alignment, reducing the risk of damage and increasing throughput, thus lowering production costs and improving the viability of solar energy.

Implementation Method 1

electroplating copper is normally a simple procedure

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 2

electroplating process for solar cells

Methodology Applied

Scientific EffectElectrochemical reduction: Electrolysis

Implementation Method 3

magnets can be distributed within the first and second frames to allow the first and second frames to be quickly and securely coupled together

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentUS10301740B2Systems, methods and apparatus for electroplating photovoltaic cells

Publication Date: 2019.05.28 TESLA INC

AI summary

A two piece electroplating frame or electroplating frame is disclosed that is suitable for holding multiple solar cells during an electroplating operation. The electroplating frame can be formed from or at least covered with non-conductive material to reduce the collection of plating material on the electroplating frame. The two pieces of the electroplating frame can be coupled together around the solar cells by magnets distributed throughout the electroplating frame. The electroplating frame can include alignment features for self-aligning the assembly of the two pieces without requiring precise pre-alignment.