Serpentine Wire Current Collector Fabrication via Collapsible Link System
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Solution Overview
Problem
Current photovoltaic cell fabrication processes face challenges in efficiently forming serpentine wire current collectors and interconnects for solar cells, which are crucial for high-throughput production and optimal current collection, due to issues with wire alignment, material strain, and uniformity.
Innovation Solution
The development of high-throughput apparatuses that utilize collapsible link systems with link heads to form serpentine wire configurations, including a recirculation path with collapsible links, rotatable drum assemblies, and guide track systems to maintain link head orientation and wire alignment, ensuring uniform pitch and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wire forming methods are used, then device complexity is reduced, but manufacturing precision and uniformity of serpentine wire pitch deteriorate
Solution Approach 1:
The wire forming system is segmented into multiple discrete link heads, each capable of independently engaging and positioning the wire. This segmentation allows precise control over the serpentine wire pitch by adjusting individual link head positions, thereby improving manufacturing precision while managing device complexity through modular design.
Solution Approach 2:
The link heads are pre-configured with engaging members positioned at specific intervals along the wire path. This preliminary arrangement of components ensures that the serpentine wire is formed with uniform pitch from the outset, eliminating the need for complex real-time adjustments and reducing overall system complexity.
2Productivity
If high-speed wire fabrication is implemented, then productivity increases, but wire alignment and material strain control worsen
Solution Approach 1:
The wire fabrication process maintains continuous motion through the link head system, with wire feeding and serpentine formation occurring simultaneously at high speed. This continuous action eliminates stopping and starting, maintaining wire alignment consistency while maximizing productivity throughput.
Solution Approach 2:
The engaging members of the link heads are designed to automatically grip and release the wire through spring-loaded or cam-actuated mechanisms. This self-service wire handling eliminates the need for external alignment adjustments during high-speed operation, maintaining precision while maximizing productivity.
3Manufacturing precision
If recirculating link system is used, then manufacturing precision is improved, but device complexity and energy consumption increase
Solution Approach 1:
The recirculating link system operates through periodic cycles of wire engagement, serpentine formation, and link return. This periodic operation allows the system to maintain precise wire formation during the active phase while minimizing energy consumption during the return phase, balancing manufacturing precision with energy efficiency.
Data Source
AI summary
Provided herein are high throughput apparatuses for fabricating wire current collector and/or interconnect assemblies for solar cells. In certain embodiments, the wire assemblies include uniformly pitched serpentine wires. According to various embodiments, the apparatuses include a plurality of link heads connected to collapsible links, with the heads spaced apart when the links are in an uncollapsed position and stacked when the links are in a collapsed position. Alternating link heads engage opposite sides of the wire such that, when collapsed, the wire is threaded through engaging members of the heads in a serpentine configuration.