Screen Printing Stroke Coordination for Faster Solar Cell Throughput
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Solution Overview
Problem
The productivity and throughput of solar cell manufacturing are limited by the cycle time of the processing cycle, particularly due to time-consuming alignments of multiple devices during the deposition and material processing phases in screen printing.
Innovation Solution
The method involves a process head assembly with a deposition device, material processing device, and substrate support that move in coordinated phases, hiding vertical movements during the initial phase to reduce cycle time, allowing simultaneous material transfer and processing, thereby optimizing the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple devices are aligned sequentially during deposition and material processing phases, then manufacturing precision is maintained, but productivity is reduced due to increased cycle time
Solution Approach 1:
The screen device and substrate support are moved in the second direction (perpendicular to printing direction) during the first phase (material processing phase) before the actual deposition occurs. This preliminary positioning action happens concurrently with material processing, so when the deposition phase begins, all devices are already aligned and ready, eliminating sequential alignment delays while maintaining precision
Solution Approach 2:
The patent implements continuous motion of the screen device and substrate support during both phases of the stroke. Instead of stopping for alignment between phases, the devices maintain continuous movement in the second direction, ensuring that alignment and deposition operations overlap in time, thereby maintaining productivity while achieving precise material transfer
2Manufacturing precision
If vertical movements of devices are performed during the deposition phase, then material transfer precision is improved, but cycle time is increased
Solution Approach 1:
Vertical positioning movements of the screen device and substrate support in the second direction are performed during the first phase (material processing phase) before deposition. This preliminary action ensures that all alignment movements are completed before material transfer begins, allowing deposition to occur without interruption or additional positioning time, thus reducing cycle time while maintaining precision
3Manufacturing precision
If material processing and material transfer are performed in separate phases, then processing quality is maintained, but productivity is reduced due to sequential operations
Solution Approach 1:
The patent merges material processing and material transfer operations into a single continuous stroke. The screen device and substrate support move together in the second direction during both phases, allowing material processing (first phase) and material transfer (second phase) to occur in sequence within one continuous motion cycle, eliminating the need for separate alignment and positioning cycles between operations
Data Source
AI summary
A method for screen printing of a material on a substrate is provided. The method includes moving a process head assembly having at least one deposition device from a first position to a second position to perform a stroke, wherein the stroke includes at least a first phase for material processing of a material on a screen device using the at least one deposition device and a second phase for a material transfer from the screen device to the substrate. The at least one deposition device moves in a first direction in the first phase. At least one device moves in a second direction perpendicular to the first direction in the first phase. The at least one deposition device and the at least one device simultaneously move during at least a part of the first phase. The at least one device is selected from the group including the at least one deposition device, a material processing device, the screen device, and a substrate support.