Integrated PV Cell Scribing and Adhesive Printing Alignment
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Solution Overview
Problem
The existing processes for manufacturing photovoltaic (PV) cells require sequential operations for laser cutting and bonding, which leads to inefficiencies such as duplicated alignment tasks, increased manufacturing floor footprint, and a higher likelihood of cell breakage due to manual handling.
Innovation Solution
A multi-operation tool that integrates a laser scribing station and an adhesive printing station within a single apparatus, allowing for continuous processing of PV cells along a conveyor system, reducing the need for manual handling and minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sequential processing by different tools is used, then each operation can be performed with dedicated equipment, but manufacturing floor footprint increases and productivity decreases
Solution Approach 1:
The patent combines laser scribing and adhesive printing operations into a single integrated tool with a unified platform. The laser module and adhesive printing module share the same positioning system and platform, allowing both operations to be performed on the same PV cell without relocation. This merging eliminates the need for separate dedicated tools while maintaining operational effectiveness, thereby reducing floor footprint and improving productivity.
2Ease of manufacture
If sequential processing by different tools is used, then each operation can be optimized independently, but manufacturing floor footprint increases
Solution Approach 1:
The integrated tool merges laser scribing and adhesive printing into a compact unified system that occupies significantly less floor space than separate tools. The shared platform and positioning system reduce the overall footprint while maintaining the ability to independently optimize each operation through dedicated modules and control systems.
Solution Approach 2:
The unified platform serves multiple functions by accommodating both laser scribing and adhesive printing operations. The positioning system and platform are designed to support various processing modules, making the system universal and space-efficient compared to dedicated single-function tools.
3Adaptability or versatility
If manual handling and relocation of cells between tools is required, then flexibility in processing is maintained, but cell breakage likelihood increases
Solution Approach 1:
By merging multiple operations into a single tool with a shared platform, the patent eliminates the need to manually handle and relocate PV cells between different tools. The cell remains on the same platform throughout the processing sequence, significantly reducing the risk of breakage while maintaining processing flexibility through programmable operation sequences.
Solution Approach 2:
The integrated tool enables continuous processing of PV cells through multiple operations without interruption or relocation. The cell undergoes laser scribing, adhesive printing, and other operations in sequence on the same platform, maintaining continuous useful action and eliminating breaks in the process that could lead to cell damage.
4Adaptability or versatility
If cells are relocated between tools, then different processing conditions can be applied, but alignment tasks must be repeated
Solution Approach 1:
The integrated tool combines multiple processing modules on a single platform, allowing different processing conditions to be applied while maintaining a single alignment reference. The laser module and adhesive printing module both operate relative to the same platform coordinate system, eliminating the need to repeat alignment tasks when transitioning between operations.
Solution Approach 2:
The system performs preliminary alignment of the PV cell on the unified platform before processing begins. Once aligned, the cell remains in the same position for all subsequent operations, and the different processing modules are calibrated to operate relative to this single alignment reference, eliminating the need for repeated alignment.
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 integrated approach enhances manufacturing efficiency by reducing the likelihood of cell breakage, improving yields, and optimizing the use of manufacturing space, while allowing for precise alignment and processing without realignment between stages.
Implementation Method 1
a laser head over a lasing location to direct a laser beam to scribe a scribe line on a surface of the PV cell
Implementation Method 2
a printer head over a printing location to direct an adhesive to a location on the surface of the PV cell
Data Source
AI summary
Multi-operation tools for photovoltaic cell processing are described. In an example, a multi-operation tool includes a conveyor system to move a photovoltaic (PV) cell continuously along a conveyor path through a laser scribing station and an adhesive printing station. Furthermore, the PV cell may be aligned to a laser head of the laser scribing station and a printer head of the adhesive printing station in a single alignment operation prior to being laser scribed and printed with an adhesive in a continuous process.