Pressurized Heated Rolling Press for Photovoltaic Cell Assembly
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Solution Overview
Problem
Current manufacturing processes for photovoltaic cells face challenges in achieving high yields without damaging sensitive components, particularly in environments that require manual handling or high temperatures, and often result in lower productivity due to the use of manual or automated methods that can cause breakage or require additional steps.
Innovation Solution
A flexible component feeder system using a vacuum conveyor and moving belt arrangement applies controlled pressure for assembly and curing, eliminating the need for physical devices like weights or clamps, and allowing for higher throughput and reduced risk of component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling is used for sensitive photovoltaic components, then component damage is reduced, but productivity and processing speed decrease
Solution Approach 1:
The patent replaces traditional mechanical pressure application systems (weights, clamps) with a pneumatic system that uses controlled air pressure to apply force to photovoltaic components during lamination. This substitution eliminates the need for direct mechanical contact that could damage sensitive components while maintaining the necessary pressure for assembly, thereby improving both component integrity and processing efficiency
Solution Approach 2:
The invention employs a pneumatic pressurization system where compressed air is directed through a platen to apply uniform pressure to the photovoltaic components during the lamination process. This pneumatic approach allows for precise control of pressure magnitude and duration, enabling high-speed automated processing without the risk of mechanical damage associated with traditional weighing or clamping methods
2Productivity
If automated assembly processes are used for photovoltaic cells, then productivity increases, but component breakage and damage increase
Solution Approach 1:
The patent replaces direct mechanical contact systems with a pneumatic pressure application system that can automatically control the magnitude and distribution of force applied to photovoltaic components. This allows automated high-speed assembly while maintaining component integrity through precisely controlled air pressure rather than uncontrolled mechanical force
Solution Approach 2:
The invention changes the physical state and control parameters of pressure application by using compressible gas instead of solid mechanical contact. The system can dynamically adjust pressure parameters (magnitude, duration, distribution) to match the specific requirements of different photovoltaic component configurations, enabling automated processing with optimized protection against damage
3Stress or pressure
If traditional pressure application methods (weights, clamps) are used, then assembly pressure is achieved, but device complexity and processing time increase
Solution Approach 1:
The patent uses a pneumatic system where compressed air is delivered through a platen to apply assembly pressure to photovoltaic components. This eliminates the need for complex mechanical pressure application devices such as weights, clamps, or hydraulic systems, significantly reducing device complexity while maintaining effective pressure application for lamination
Solution Approach 2:
The invention extracts and removes the complex mechanical pressure application mechanisms (weights, clamps, hydraulic systems) from the assembly process, replacing them with a simple pneumatic system that delivers pressure through compressed air. This extraction of unnecessary complexity simplifies the overall system while achieving the same functional outcome
4Reliability
If manual assembly processes are used in high temperature environments, then component sensitivity is protected, but operator safety and productivity are compromised
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated pneumatic lamination system that can operate in high temperature environments. The pneumatic system applies pressure through compressed air without requiring human presence in the hot zone, eliminating thermal exposure risks to operators while maintaining precise control over the assembly process
Solution Approach 2:
The invention implements an automated system where the pneumatic lamination apparatus performs the assembly operation independently without human intervention. The system self-regulates pressure application and can operate autonomously in high temperature curing environments, protecting operators from thermal hazards while ensuring consistent component handling
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 enhances assembly efficiency by reducing component damage and increasing processing speed, enabling safer handling of sensitive components and improved yields without the need for physical pressure devices, while allowing for both automated and human interaction.
Implementation Method 1
a vacuum conveyor for receiving the plurality of materials at the first location
Implementation Method 2
a vacuum pressure source for applying a predetermined vacuum pressure from at least one of the plurality of openings towards the moving belt and the vacuum conveyor as the plurality of materials are conveyed from the second location to a third location, creating a force compressing the plurality of materials
Implementation Method 3
a curing source at a second location for curing the compressed plurality of materials
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A flexible component feeder source for providing materials to an assembly process is disclosed. The flexible component feeder source comprises a flexible base suitable for protecting and receiving one or more photovoltaic cells for processing, wherein the flexible base is of a linear shape when opened and forms a roll when rolled.