Solar Cell Wet Pattern Printing With In-Line 3D Paste Control
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Solution Overview
Problem
Current methods for printing solar cells face inefficiencies in material consumption and quality control, particularly due to manual or infrequent measurements of paste laydown, leading to suboptimal production efficiency and increased costs.
Innovation Solution
Implementing an in-line 3D scanning system using a laser profilometer to extract real-time three-dimensional morphological data of the wet pattern, allowing for precise control of the printing process and optimization of material consumption by determining and adjusting the paste laydown in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual or offline weighing methods are used to measure paste laydown, then measurement can be performed, but measurement precision and productivity are poor
Solution Approach 1:
The patent replaces mechanical weighing systems with an optical 3D profilometer system that uses light to measure paste morphology. The profilometer captures optical images of the paste on the substrate and processes these images to determine paste volume, area, and height, eliminating the need for physical weighing while achieving higher precision and real-time measurement capability
Solution Approach 2:
The patent introduces an intermediary optical measurement system between the printing process and quality control. The 3D profilometer acts as an intermediary that non-contactively measures paste morphology by capturing light reflections and refractions from the paste surface, converting optical information into quantitative measurement data without disrupting production flow
2Reliability
If high conductivity material like silver paste is used for busbars and fingers, then electrical conductivity is improved, but material consumption and cost increase
Solution Approach 1:
The patent implements a feedback control system where the 3D profilometer continuously monitors paste application in real-time, and this measurement data feeds back to the printing process to adjust paste deposition parameters. This closed-loop feedback ensures that the minimum necessary amount of expensive silver paste is applied while maintaining required conductivity standards
Solution Approach 2:
The patent changes the measurement parameters from indirect weight-based measurements to direct 3D morphological measurements of paste volume, area, and height. This parameter change enables precise quantification of paste consumption and allows optimization of paste application parameters to reduce material waste while maintaining electrical performance
3Quantity of substance
If double weighing is performed before and after printing to measure paste amount, then material consumption can be determined, but time loss and productivity reduction occur
Solution Approach 1:
The patent performs preliminary measurement of the substrate before paste application and immediately after printing, using the 3D profilometer to capture the difference in paste morphology. This preliminary action approach allows for rapid measurement without requiring lengthy weighing procedures, reducing measurement time while accurately determining paste consumption
Solution Approach 2:
The patent substitutes the mechanical weighing process with an optical 3D scanning system that rapidly captures surface morphology data. The profilometer can measure paste dimensions in seconds by analyzing optical images, replacing the time-consuming double weighing process while providing more detailed information about paste distribution and morphology
4Manufacturing precision
If real-time control of printing is implemented based on morphological data, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the 3D profilometer system to perform multiple functions: measuring paste height, width, area, volume, and morphology in a single integrated device. The system also serves as both a measurement tool and a control input for the printing process, reducing the need for separate measurement and control systems while achieving real-time manufacturing precision
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 real-time process control, reduces material waste, improves production efficiency, and ensures consistent quality by monitoring and adjusting the paste laydown dynamically, thereby optimizing material usage and reducing operational costs.
Implementation Method 1
extracting three-dimensional morphological data of the wet pattern in real-time using an in-line profilometer
Data Source
AI summary
A method (500) for printing on a substrate (102) for the production of a solar cell, the method comprising: printing (501) a wet pattern on the substrate (102); extracting (503) three-dimensional morphological data of the wet pattern (104′) in real-time using an in-line profilometer (101); wherein the printing of the wet pattern on the substrate is controlled in real time at least in part based on previous three-dimensional morphological data obtained by extracting the three-dimensional morphological data.