Roller-Based Microelectronic Device Transfer System
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Solution Overview
Problem
The high cost of photovoltaic systems limits their competitiveness with fossil-fuel generated electricity, and current assembly methods for solar cells are costly due to the need for precise placement of small cells, which increases material costs when trying to assemble larger cells.
Innovation Solution
A system and method for massively parallel placement of microelectronic devices, such as solar cells, using a roller with pre-determined openings to transfer and deposit cells onto a receiving substrate, allowing for the application of conducting and insulating layers to create desired electrical connections and improve mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pick-and-place assembly techniques are used to individually place each solar cell, then assembly precision is improved, but assembly cost increases
Solution Approach 1:
The invention segments the solar cells into arrays on a donor substrate, with each cell having release structures that allow individual transfer. This segmentation enables precise placement of each cell while using a cost-effective array-based transfer method instead of expensive individual pick-and-place operations.
Solution Approach 2:
The invention introduces a donor substrate as an intermediary carrier that holds multiple solar cells in an array. This intermediary allows cells to be transferred en masse to the receiver substrate, reducing assembly costs while maintaining precision through the structured array configuration and release mechanisms.
2Ease of manufacture
If larger solar cell sizes are used, then assembly cost is reduced, but material cost increases
Solution Approach 1:
The invention transitions from assembling individual cells to assembling cell arrays in a two-dimensional configuration on the donor substrate. This dimensional change allows multiple cells to be handled simultaneously, reducing assembly costs while enabling flexible cell size selection without the trade-off present in traditional methods.
3Manufacturing precision
If mechanical and surface chemistry driven techniques are used for assembly, then assembly precision is improved, but assembly complexity increases
Solution Approach 1:
The invention employs self-assembling release structures where the solar cells automatically release from the donor substrate at predetermined locations through mechanical or surface chemistry mechanisms. This self-service approach achieves precise assembly without requiring complex external manipulation systems for each individual cell.
Solution Approach 2:
The release structures are pre-configured on the donor substrate before cell placement. This preliminary action establishes the transfer mechanism in advance, allowing cells to be released and transferred automatically at the correct locations, thereby reducing assembly complexity while maintaining precision.
Data Source
AI summary
An apparatus including a carrier substrate configured to move a microelectronic device. The apparatus further includes a rotatable body configured to receive the microelectronic device. Additionally, the apparatus includes a second substrate configured to receive the microelectronic device from the rotatable body.