Solar Cell Chip Arrangement with Integrated Slicing and Vacuum Pickup
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Solution Overview
Problem
The manufacturing process of silicon-based flexible solar cells is complex and inefficient, requiring multiple steps for chip slicing and arrangement, which hampers automation efficiency.
Innovation Solution
A solar cell chip arrangement machine that integrates chip slicing and arrangement by using a feeding mechanism with a servo-controlled push block and a slicing mechanism with a vacuum sucker, guide plates, and low-viscosity tape to simplify the process and improve precision and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the traditional manufacturing process is used to slice chips first and then arrange them, then the chip arrangement can be completed, but the number of processes is large and automation efficiency is low
Solution Approach 1:
The patent combines the chip slicing function and chip arrangement function into a single integrated machine system. The slicing mechanism with cutting blade performs slicing while the arrangement mechanism with suction cup simultaneously handles chip positioning and transfer, merging two separate processes into one coordinated operation that reduces total process steps and improves automation efficiency
Solution Approach 2:
The arrangement mechanism is designed to perform chip positioning and arrangement actions in advance while the slicing operation is still in progress. The suction cup mechanism prepares to grasp and position chips before the slicing is completely finished, allowing overlapping of operations that reduces total cycle time and improves productivity
2Productivity
If multiple chips are arranged simultaneously to improve efficiency, then productivity increases, but positioning precision becomes difficult to maintain
Solution Approach 1:
The patent introduces a vacuum suction cup as an intermediary mechanism between the chip slicing and chip arrangement operations. The suction cup uniformly grasps multiple chips simultaneously through vacuum pressure, ensuring that all chips are held in their correct relative positions during transfer, thereby maintaining positioning precision while enabling multi-chip simultaneous handling
Solution Approach 2:
The arrangement mechanism uses a flat positioning surface with multiple positioning holes arranged in precise patterns. All chips are positioned on the same plane (equipotential surface) with uniform spacing, ensuring that gravitational forces and other external forces affect all chips equally, thereby maintaining consistent positioning precision across multiple simultaneous arrangements
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 integration reduces the number of processes, allows for simultaneous handling and arrangement of multiple chips, enhancing automation and efficiency by simplifying the preparation process and achieving high precision in chip placement.
Implementation Method 1
The slicing mechanism includes a vacuum sucker, a guide plate, a guide plate slide rail, a positioning block, a positioning block slide rail, a cylinder, a fixed plate, and a vacuum generator. The vacuum sucker is arranged on the positioning block, and the vacuum sucker is connected to the vacuum generator.
Data Source
AI summary
A solar cell chip arrangement machine includes a feeding mechanism and a slicing mechanism. The feeding mechanism includes a whole battery piece. A push block is connected to the back of the whole battery piece, and a pressing plate is arranged above the front of the whole battery piece. The slicing mechanism is arranged on the pressing plate above the front of the whole battery piece. The slicing mechanism includes a vacuum sucker, a guide plate, a guide plate slide rail, a positioning block, a positioning block slide rail, a cylinder, a fixed plate, and a vacuum generator. The positioning block is arranged on the positioning block slide rail, a pulley is arranged on the positioning block, and the guide plate is provided with a limit slot corresponding to the pulley. The vacuum sucker is arranged on the positioning block, and the vacuum sucker is connected to the vacuum generator.