Solar Cell Electroplating Stability via Bonded Plating Assemblies

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing solar cell electroplating processes face challenges such as mechanical instability, warping, chemical drag-out, and reduced throughput due to the need for precise handling and individual processing of solar cells during metal electrode formation.

Innovation Solution

A method involving the formation of a plating assembly by attaching two solar cells with a bonding agent, allowing them to be treated as a single unit in an electroplating process, which increases mechanical stability, minimizes warping, reduces chemical exposure, and enhances processing efficiency by enabling simultaneous electroplating of two cells per clip without the need for a plating jig.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If solar cells are processed individually during electroplating, then handling precision can be maintained, but mechanical instability and warping occur

Engineering Contradiction:

Improvemechanical stabilityVSAvoidhandling precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

Multiple solar cells are merged into a single plating assembly by bonding them together, allowing them to be handled as one unit during electroplating. This combining approach provides mechanical stability while maintaining handling precision, as the assembly can be gripped at multiple points without requiring precise handling of each individual cell.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plating assembly is segmented into multiple solar cells that are bonded together, with each cell being separable after plating. This segmentation allows the assembly to be handled as a stable unit during processing while enabling individual cell extraction afterward, resolving the contradiction between stability and precision handling.

Inventive Principle:

Principle #1Segmentation

2Productivity

If solar cells are processed individually, then processing accuracy can be maintained, but throughput is reduced

Engineering Contradiction:

ImprovethroughputVSAvoidprocessing accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Multiple solar cells are combined into a single plating assembly that can be electroplated simultaneously in one operation. This merging approach increases throughput by processing multiple cells at once while maintaining processing accuracy through consistent bonding and uniform electrical connection across all cells in the assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plating assembly serves multiple functions: it provides mechanical stability, enables simultaneous electroplating of multiple cells, and maintains electrical connectivity for all cells. This multi-functionality increases throughput without sacrificing processing accuracy, as the assembly can be handled and processed as a single unit.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If precise handling is required for individual cells, then manufacturing accuracy is maintained, but mechanical instability occurs

Engineering Contradiction:

Improvehandling accuracyVSAvoidmechanical stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

Solar cells are merged into a rigid plating assembly through bonding, which provides mechanical stability while maintaining handling accuracy. The bonded structure distributes mechanical loads across multiple cells, preventing instability that would occur with individual cell handling, while the assembly can still be precisely positioned and handled as a unit.

Inventive Principle:

Principle #5Merging (Combining)

4Loss of substance

If individual cells are processed separately, then processing precision is maintained, but chemical drag-out increases

Engineering Contradiction:

Improvechemical drag-outVSAvoidprocessing precision

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

Multiple solar cells are combined into a single plating assembly, reducing the total surface area exposed to chemicals during electroplating. This merging approach minimizes chemical drag-out by decreasing the overall chemical consumption and waste, while the assembly maintains processing precision through uniform bonding and consistent electrical connections across all cells.

Inventive Principle:

Principle #5Merging (Combining)

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 approach improves the mechanical stability and throughput of the electroplating process, reduces warping and chemical drag-out, and allows for efficient electroplating of two solar cells per clip, increasing overall production efficiency.

Implementation Method 1

The plating assembly is passed through a plating chamber to electroplate metal on a second side of the first solar cell and on a second side of the second solar cell

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS11127871B2Structures and methods for forming electrodes of solar cells

Publication Date: 2021.09.21 MAXEON SOLAR PTE LTD

AI summary

Solar cells are attached together to form a plating assembly. The plating assembly is attached to a belt, which transports the plating assembly through a plating chamber where metal is electroplated on the solar cells. The electroplated metal is patterned to form metal contact fingers. After the metal is electroplated, the plating assembly is singulated to separate the two solar cells.