Solar Cell Transfer System With Sealed Tank Receptacle
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Solution Overview
Problem
Conventional solar cell fabrication processes are time-consuming and prone to errors, and the transfer and storage of solar cells are challenging due to degradation caused by exposure to ambient air, leading to costly and inefficient large-scale production.
Innovation Solution
A solar cell transfer system with a tank receptacle and conveyor system that maintains a controlled environment, using elevators and robotic arms to securely transfer solar cells between fabrication lines and storage pods while minimizing exposure to ambient air, utilizing sensors and actuators for precise control and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solar cell components are placed in a large storage container that is purged and filled with inert gas, then the components are protected from oxidation, but the purging and filling process becomes time-consuming and costly
Solution Approach 1:
The system divides the storage function into multiple small sealed containers (individual trays or pockets) rather than one large container. Each small container can be independently sealed and filled with inert gas, allowing parallel processing and reducing the total time required compared to purging a single large container.
Solution Approach 2:
The inert gas filling is performed in advance during the sealing process itself, rather than requiring a separate purging operation later. The containers are sealed with inert gas already inside, eliminating the need for time-consuming post-sealing purging operations.
2Quantity of substance
If solar cell components are stored in a large storage container, then large volumes can be stored, but the purging and filling of the container becomes cost prohibitive
Solution Approach 1:
The system uses multiple small sealed containers instead of one large container. This segmentation allows inert gas to be filled into many small volumes simultaneously or in parallel batches, dramatically reducing the total time and cost of inert gas processing while maintaining the ability to store large quantities of solar cell components.
Solution Approach 2:
Each small container is independently sealed and filled, allowing the system to process containers autonomously without requiring a centralized, time-consuming purging operation for the entire storage volume. This self-service approach reduces labor and operational costs.
3Adaptability or versatility
If manual fabrication processes are used, then flexibility is maintained, but the process becomes time-consuming and error-prone
Solution Approach 1:
The system introduces automated material handling equipment (conveyors, robotic arms, transfer mechanisms) as intermediaries between fabrication stations. These intermediaries enable automated transfer of solar cell components while maintaining the flexibility to program different fabrication sequences and accommodate various cell types, thus improving productivity without sacrificing adaptability.
Data Source
AI summary
Systems and methods for transferring solar cells while maintaining a controlled micro-environment are provided. In particular, such systems provide automated loading and unloading of solar cells by use of a conveyor and elevator within a tank receptacle sealingly connected with a solar cell carrying pods and a flow tube of solar cell components in a solar cell fabrication process. The tank receptacle can include one or more ports for sealingly and operably coupling with a cover of a solar cell carrying pod, each port having an elevator for withdrawing a removable base of the pod along with a solar cell carrying cassette into the tank and a conveyor to facilitate loading and/or unloading of solar cells with the cassette by coordinated movement of the elevator and conveyor. Such systems can further include a robotic arm having a gripper and nozzle to maintain a micro-environment within the pod during transport.