Solar Panel Carrier for Layer Alignment
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Solution Overview
Problem
Existing methods for producing solar panels face challenges in maintaining the correct construction of loosely stacked components during assembly, leading to potential misalignment and faulty electrical connections due to conveying movements and heating processes.
Innovation Solution
A method utilizing a flat carrier with electric conducting means, insulating thermoplastic layers, and a light-transmitting support layer to securely maintain component orientation, followed by partial bonding and heating to achieve a stable stack configuration, allowing for reliable electrical connections and eventual curing under excess pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are loosely stacked during assembly, then ease of assembly is improved, but manufacturing precision deteriorates due to misalignment during conveying movements
Solution Approach 1:
The patent applies preliminary action by pre-assembling the solar cells and connecting them to the rear layer while the stack is still in a loosely stacked position on the carrier. This preliminary assembly is performed before the components are rigidly fixed, allowing easy assembly during construction while maintaining alignment through the carrier support. The components are connected in advance while still accessible and movable, then the entire stack is later rigidized to maintain this pre-established alignment.
2Manufacturing precision
If components are rigidly fixed during assembly, then manufacturing precision is improved, but device complexity increases due to additional fixing mechanisms
Solution Approach 1:
The patent extracts the fixing function from the assembly process itself and separates it into a distinct subsequent step. The components are first assembled in a loosely stacked state without complex fixing mechanisms, allowing simple and easy assembly. Only after the complete stack is assembled and aligned on the carrier does the process rigidize the entire stack as a unified structure, eliminating the need for intermediate fixing mechanisms between individual components.
Solution Approach 2:
The patent merges all components (rear layer, solar cells, connecting elements, front layer) into a single rigidized stack structure after assembly. Instead of fixing each component individually with separate mechanisms, the entire assembly is rigidized together as one unit, maintaining the alignment achieved during loose stacking while simplifying the fixing process to a single collective operation.
3Ease of manufacture
If components are loosely stacked, then ease of assembly is improved, but reliability deteriorates due to potential shifting during conveying movements
Solution Approach 1:
The patent performs the critical connection action preliminarily while components are loosely stacked and easily accessible. The solar cells are connected to the rear layer and to each other in series before the stack is rigidized. This preliminary connection ensures reliable electrical connections are established when components are still easy to position and adjust, and these connections are then protected from shifting when the entire stack is rigidized as a unified structure.
4Reliability
If components are rigidly fixed early in the process, then reliability is improved, but ease of manufacture deteriorates due to difficulty in assembly adjustments
Solution Approach 1:
The patent performs all assembly operations as preliminary actions before the rigidizing step. The solar cells are positioned, connected to the rear layer, and interconnected in series while the stack remains loosely assembled and flexible. Only after all assembly operations are complete does the process rigidize the stack, locking in the connections. This sequence ensures assembly flexibility is maintained during the entire assembly process, and reliability is achieved through the final rigidization that protects the pre-established connections.
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
Ensures accurate component alignment and reliable electrical connections throughout the production process, enabling the creation of a stable and functional solar panel with improved handling and bonding of layers.
Implementation Method 1
at most partially melting the thermoplastic layers under the effect of heat before turning over the carrier
Implementation Method 2
at most partially bonding or fixing the stack by cooling down the thermoplastic layers
Implementation Method 3
By means of such solar cells or photovoltaic cells, solar radiation can be transformed into electric power
Implementation Method 4
the film layer, which usually consists of ethylene vinyl acetate, is cured
Implementation Method 5
Such a stack is heated in an oven
Implementation Method 6
the stack is heated and subjected to excess pressure
Data Source
AI summary
The invention relates to the production of solar panels which comprise solar cells connected to one another. In this case, various layers are stacked onto one another, such as a film layer, bonding agent, insulating film, solar cells and a support layer. Combining all these layers to form the final panel is carried out on a carrier which stabilizes and supports the stack while it is conveyed past the various treatment stations. The turning over of the stack can also be carried out in a reliable manner by means of such a carrier without shifts between the various components with respect to one another occurring.