Solar Module Structuring Device with Adjustable Track Spacing
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Solution Overview
Problem
The challenge in structuring thin-film solar modules lies in maintaining the parallelism and constant distance of tracks introduced during multiple process steps, particularly after high-temperature steps that cause distortion, making it difficult to ensure precise alignment of additional tracks relative to existing ones.
Innovation Solution
A structuring device with independently controllable structuring units, each equipped with multiple tools, allows for the subdivision of tracks into local groups, enabling flexible control and adjustment of track courses to maintain parallelism and constant distance, using a combination of mechanical and laser processing tools, and employing a track detection and control system to align new tracks with existing ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple structuring steps are performed with laser processing units to introduce parallel tracks, then tracks can be introduced efficiently, but high-temperature steps cause distortion of the solar module making tracks no longer parallel
Solution Approach 1:
The patent applies preliminary action by introducing compensation values before the actual structuring process. The system pre-calculates distortion compensation based on thermal model predictions, storing these values in a memory unit before processing begins. This allows the system to proactively counteract expected thermal distortion rather than reacting to it after damage occurs.
Solution Approach 2:
The patent implements feedback through a closed-loop control system that continuously monitors and adjusts track positioning. A detection unit measures actual track positions and compares them against desired positions, with the control unit using this feedback information to calculate and apply real-time compensation values, ensuring tracks remain parallel despite thermal distortion.
2Adaptability or versatility
If parallel tracks are introduced in multiple process steps, then complex structuring is achieved, but maintaining constant distance between tracks becomes difficult due to thermal distortion
Solution Approach 1:
The patent applies local quality by implementing individual compensation values for each track rather than a uniform adjustment. The system detects and calculates specific compensation values for each track position based on local thermal distortion characteristics, allowing different parts of the module to be compensated according to their specific distortion patterns.
Solution Approach 2:
The patent changes parameters dynamically by adjusting track positioning parameters in real-time based on detected distortion. The control unit modifies processing parameters such as track position coordinates and spacing values according to the measured distortion state, enabling the system to maintain constant distance between tracks despite thermal effects.
3Speed
If laser processing units are used for structuring, then tracks can be introduced quickly, but thermal effects during processing cause distortion of the solar module
Solution Approach 1:
The patent converts the harmful thermal distortion effect into a beneficial predictive model. By measuring and analyzing thermal distortion patterns, the system builds a thermal model that predicts distortion behavior, then uses this knowledge to pre-calculate compensation values that turn the previously harmful thermal effect into a controllable and compensatable parameter.
Solution Approach 2:
The system performs preliminary thermal modeling and compensation calculation before the actual laser processing begins. This preliminary action allows the system to prepare compensation strategies in advance, maintaining high processing speed while preemptively counteracting thermal distortion effects.
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 enables efficient and reliable introduction of new tracks that remain parallel and at a constant distance from existing tracks, even after thermal distortions, facilitating the structuring of thin-film solar modules with high precision and accuracy.
Implementation Method 1
At least one first processing unit (P1) for introducing a number of first tracks (t1' to t4') into a first layer (11) of the solar module (1) by means of a laser beam (2)
Implementation Method 2
by means of a laser head (or several laser heads working in parallel)
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The present invention relates to a structuring device for structuring a plate-shaped element (E), in particular a solar module and/or a thin-film solar module, comprising several structuring tools (1) each designed for introducing a track into the plate-shaped element, characterized by a first structuring unit (2a) comprising several of these structuring tools, wherein at least two structuring tools (1a, 1b) of this first structuring unit are designed such that two first tracks running parallel to each other and at a constant distance from each other can be introduced into the plate-shaped element (first track group SG1), and a second structuring unit (2b) comprising several of these structuring tools, wherein at least two structuring tools (1c, 1d) of this second structuring unit are designed such thatthat with them two second tracks running parallel to each other and at a constant distance from each other can be introduced into the plate-shaped element (second track group SG2), wherein the first and/or the second structuring unit (2a, 2b) is/are designed and/or controllable in such a way that the distance of the first track group from the second track group can be variably designed.