Magnetic Handling of Ferromagnetic Solar Substrates
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Solution Overview
Problem
Conventional photovoltaic cell fabrication processes are inefficient due to the need for numerous mechanical components, lack of control over placement and tolerances, and high maintenance requirements, which hinder the efficient production of solar modules.
Innovation Solution
The use of magnetic actuators to manipulate ferromagnetic substrates coated with thin film solar cell materials, allowing for magnetically actuated handling throughout the fabrication process, from forming photovoltaic cell layers to packaging the module, reducing mechanical components and improving control and ease of handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical handling systems are used in photovoltaic cell fabrication, then the process can be performed with traditional equipment, but the system requires numerous mechanical components, has high maintenance requirements, and lacks control over placement and tolerances
Solution Approach 1:
The patent replaces conventional mechanical handling systems with magnetic field-based manipulation. Magnetic actuators generate magnetic fields that interact with ferromagnetic substrates to move, position, and manipulate photovoltaic cell components without physical contact. This substitution eliminates numerous mechanical components such as grippers, clamps, and positioning mechanisms, while providing precise control over placement and tolerances through field-based actuation.
Solution Approach 2:
The patent introduces ferromagnetic substrates as intermediaries between the magnetic actuators and the photovoltaic cell components. These substrates are coated with thin film solar cell materials and serve as carriers that can be manipulated by magnetic fields. The ferromagnetic substrate acts as a mediator that translates magnetic field actions into precise positioning and handling of the delicate photovoltaic structures, enabling control without direct mechanical contact.
2Productivity
If conventional mechanical handling systems are used in photovoltaic cell fabrication, then the process can proceed with traditional equipment, but the maintenance requirements are high and efficiency is reduced
Solution Approach 1:
The patent replaces mechanical handling systems with magnetic field-based manipulation, eliminating numerous mechanical components that require maintenance. Magnetic actuators have no moving parts in contact with the workpiece, eliminating wear, friction, and the need for lubrication or adjustment. This substitution significantly reduces maintenance requirements while increasing fabrication efficiency through faster, more precise positioning and handling of photovoltaic components.
Solution Approach 2:
The magnetic handling system provides self-service capabilities through programmable control of magnetic field strength and positioning. The system can automatically adjust field parameters to optimize handling for different cell types and fabrication stages, eliminating the need for manual intervention or maintenance adjustments. The ferromagnetic substrates themselves serve as self-contained carriers that maintain component positioning without additional mechanical fixtures.
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 approach results in highly efficient, low-maintenance photovoltaic module fabrication processes with fewer mechanical components, greater control over placement and tolerances, and improved handling, enhancing the overall efficiency of solar module production.
Implementation Method 1
using magnetic force to constrain, move or otherwise manipulate partially fabricated cells or modules
Implementation Method 2
depositing thin film materials on a substrate to form a light absorbing layer sandwiched between electrical contact layers
Implementation Method 3
integrated into building structures or otherwise assembled to convert solar energy into electricity by the photovoltaic effect
Data Source
AI summary
Provided herein are methods, apparatuses and systems for fabricating photovoltaic cells and modules. In certain embodiments, the methods, apparatuses and systems involve coating ferromagnetic substrates with thin film solar cell materials and using magnetic force to constrain, move or otherwise manipulate partially fabricated cells or modules. According to various embodiments, the methods, apparatuses and systems provide magnetically actuated handling throughout a photovoltaic cell or module fabrication process, from forming photovoltaic cell layers on a substrate to packaging the module for transport and installation. The magnetically manipulated processing provides advantages over conventional photovoltaic module processing operations, including fewer mechanical components, greater control over placement and tolerances, and ease of handling. As a result, the methods, apparatuses and systems provide highly efficient, low maintenance photovoltaic module fabrication processes.