Solar Panel Subassembly Tacking Pads for Fixture-Free Bond Line Control
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Solution Overview
Problem
Conventional solar panel construction methods require complex and costly fixtures for aligning and curing adhesive, leading to increased manufacturing costs, labor, and rework due to the need for compressive pressure and precise adhesive application.
Innovation Solution
The method involves using pressure-sensitive tacking pads to adhere and align solar panel subassemblies, eliminating the need for external compressive pressure during adhesive curing, and utilizing a silicone elastomer adhesive with a working time of 30 minutes to 4 hours, which extends across 40% to 90% of the subassembly surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional adhesive curing methods with external compressive pressure and fixtures are used, then adhesive bond line thickness can be controlled within design tolerance, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent uses disposable spacers made of compressible material that are placed between subassemblies during adhesive application. These spacers are inexpensive, single-use components that define the bond line thickness and are removed after curing, eliminating the need for complex reusable fixtures and tooling while maintaining precise thickness control.
Solution Approach 2:
The patent introduces compressible spacers as intermediary elements between the adhesive and subassemblies. These spacers act as mediators that transfer and maintain the desired bond line thickness during adhesive curing, replacing the need for complex external pressure application systems and fixtures.
2Manufacturing precision
If external compressive pressure is applied during adhesive curing, then adhesive bond line thickness is controlled, but manufacturing time and labor costs increase
Solution Approach 1:
The patent places compressible spacers between subassemblies before applying adhesive. These pre-positioned spacers automatically maintain the correct bond line thickness during curing without requiring subsequent external pressure application or fixture adjustment, streamlining the manufacturing process and reducing cycle time.
3Manufacturing precision
If glass fillers with diameter equal to bond line thickness are used in adhesive, then adhesive thickness can be maintained, but adhesive complexity and material costs increase
Solution Approach 1:
The patent uses physical spacers as intermediaries to maintain adhesive thickness, replacing the need for glass fillers or microballoons in the adhesive formulation. This simplifies the adhesive material itself while still achieving precise thickness control through the removable spacer system.
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 simplifies solar panel construction, reduces tooling and labor costs, decreases curing time from days to hours, and maintains precise adhesive bond lines without the need for glass fillers or microballoons, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
at least one tacking pad positioned between the first solar panel subassembly and the second solar panel subassembly, and adhered to a first surface of the first solar panel subassembly
Data Source
AI summary
A method for forming a solar panel can include attaching one or more tacking pads to one or both of a first surface of a first solar panel subassembly and a second surface of a second solar panel subassembly. The method further includes dispensing an adhesive onto at least one of the first and second surfaces. The first and second surfaces are placed in contact with the one or more tacking pads, thereby tacking the first and second solar panel subassemblies together, during which the first and second surfaces contact the adhesive, thereby decreasing a thickness and increasing a surface area of the adhesive. Subsequently, the adhesive is cured. The tacking pad(s) maintain fixed alignment of the solar panel subassemblies during curing of the adhesive, and establish a bond line of the adhesive.