Solar Cell Cleaving and Adhesive Deposition for Shingled Assembly
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Solution Overview
Problem
The manufacturing process of shingled solar cell arrangements is cumbersome and has low throughput and yield due to the complexity of assembling overlapping solar cell pieces, which reduces the active area for sunlight conversion and thus the power output of solar cell systems.
Innovation Solution
A method and apparatus that utilize a cleaving system to separate solar cells into pieces and deposit electrically conductive adhesives on them, allowing for efficient assembly of overlapping solar cell pieces in a targeted configuration, increasing the active area and enhancing the power output by 20 to 40 Watts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If solar cells are assembled into shingled solar cell arrangements, then the active area for sunlight conversion is increased, but the manufacturing process becomes cumbersome with low throughput and yield
Solution Approach 1:
The solar cell is divided into multiple solar cell pieces through a cleaving process. The cleaving system uses rotating side segments with cutting elements that separate the intact solar cell into overlapping pieces, which are then arranged in a shingled configuration to increase the active area while maintaining manufacturing efficiency
Solution Approach 2:
The electrically conductive adhesive is applied to the solar cell pieces before the cleaving process. This preliminary action ensures that the adhesive is already in position on the pieces, eliminating the need for subsequent adhesive application steps and streamlining the assembly process for high throughput
2Area of stationary object
If solar cells are assembled into shingled solar cell arrangements, then the active area for sunlight conversion is increased, but the manufacturing process becomes cumbersome with low yield
Solution Approach 1:
The cleaving system divides the solar cell into multiple pieces with precise control over the separation process. The rotating side segments with cutting elements create clean, controlled separations that maintain the integrity of each piece, ensuring high yield while enabling the increased active area of shingled arrangements
Solution Approach 2:
The system incorporates feedback mechanisms to monitor and control the cleaving process, ensuring that each solar cell piece is properly separated and positioned. This feedback control maintains consistent quality and high yield throughout the manufacturing process
3Reliability
If electrical contacts are present on the front surface of solar cells, then electrical connection is enabled, but the active area for sunlight conversion is reduced
Solution Approach 1:
By dividing the solar cell into multiple overlapping pieces, the electrical contacts on the front surface occupy a smaller proportion of the total active area. The shingled configuration allows sunlight to convert to electricity across the overlapping regions, effectively reducing the relative impact of contact area on the overall active area
Solution Approach 2:
The shingled arrangement introduces an overlapping dimension to the solar cell structure. Multiple layers of solar cell pieces are stacked and bonded together, creating a three-dimensional configuration that increases the effective light-receiving surface area while the electrical contacts remain confined to specific regions on each piece
Data Source
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AI summary
A method for processing a solar cell is provided. The method includes the following operations. A solar cell (1) is held by a plurality of holding members (510, 520, 530) of a cleaving system. The plurality of holding members include a first holding member (510) and a second holding member (520). The first holding member is rotatable about a first rotation axis. The first rotation axis and the solar cell held by the plurality of holding members are disposed in a substantially same plane. At least a first rotation movement of the first holding member about the first rotation axis is performed to separate the solar cell into a plurality of solar cell pieces including a first solar cell piece (10a) and a second solar cell piece (10b). At least a second rotation movement of the first holding member in a sense opposite to the first rotation movement is performed to arrange the first solar cell piece in a target position. One or more first features (30a) are deposited on the first solar cell piece and one or more second features (30b) are deposited on the second solar cell piece while the first solar cell piece and the second solar cell piece are disposed in a same deposition area (810).