Vacuum Conveyor for Photovoltaic Cell Assembly
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Solution Overview
Problem
Current manufacturing processes for photovoltaic cell assemblies face challenges in achieving high yields without damaging sensitive components, particularly in environments that require manual handling or high temperatures, and often involve risks and inefficiencies due to the use of weights, clamps, and rollers.
Innovation Solution
A system utilizing a flexible component feeder and vacuum conveyor with a moving belt applies controlled vacuum pressure and thermal curing to connect and cure photovoltaic cells, eliminating the need for physical pressure devices and enabling safer, higher-speed processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly processes are used for photovoltaic cell assemblies, then productivity and manufacturing yield are improved, but component damage increases due to mechanical handling
Solution Approach 1:
The patent replaces traditional mechanical pressure application devices (weights, clamps, rollers) with a vacuum-based pressure system. The vacuum conveyor creates uniform distributed pressure through suction ports that hold cells in place without mechanical contact, eliminating the damage caused by mechanical handling while maintaining automated processing capability.
Solution Approach 2:
The invention uses vacuum pressure (pneumatic principle) to replace mechanical pressure systems. The vacuum conveyor with multiple suction ports creates a pneumatic field that holds and presses photovoltaic cells during assembly and curing, providing uniform pressure distribution that prevents cell damage while enabling automated high-speed processing.
2Object-affected harmful factors
If manual handling is used for sensitive photovoltaic components, then component damage is reduced, but productivity and manufacturing yield decrease
Solution Approach 1:
The vacuum-based system replaces manual mechanical handling with a pneumatic field that gently holds and positions cells. The distributed vacuum pressure through multiple suction ports provides secure holding without point-contact damage, enabling automated processing at high speeds while maintaining the gentle handling characteristics of manual processes.
3Stress or pressure
If traditional pressure devices (weights, clamps, rollers) are used for curing, then assembly pressure is achieved, but operational risks and component damage increase
Solution Approach 1:
The invention replaces traditional mechanical pressure devices (weights, clamps, rollers) with a vacuum-based pressure system. The vacuum conveyor creates uniform distributed pressure through suction ports that hold cells in place without mechanical contact, eliminating operational risks associated with heavy weights and complex mechanical clamping systems while maintaining consistent assembly pressure during curing.
Solution Approach 2:
The system changes the physical parameter of pressure application from mechanical contact force to pneumatic suction force. This parameter change transforms the pressure distribution from localized mechanical contact points to uniform distributed pressure across the cell surface, reducing stress concentrations that cause damage while maintaining effective assembly pressure.
4Power
If high temperatures are used for curing, then curing efficiency is improved, but operational safety deteriorates due to hazardous environments
Solution Approach 1:
The vacuum-based holding and positioning system enables automated high-speed processing that reduces total curing time requirements. By efficiently holding and positioning cells without mechanical damage, the system allows for optimized curing cycles that maintain high curing efficiency while reducing exposure time to high temperatures, thereby improving operational safety.
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 enhances assembly yield and throughput while reducing component damage and operational risks, allowing for safer automation in environments previously hazardous to human intervention.
Implementation Method 1
A vacuum conveyor and moving belt are utilized in a predetermined relational arrangement and driven in a predetermined relational arrangement to convey a plurality of materials from a first location to a second location. A vacuum pressure source applies a predetermined vacuum pressure from at least one of the plurality of openings toward the moving belt and vacuum conveyor as the plurality of materials are conveyed from the second location to a third location, creating a force compressing the plurality of materials.
Implementation Method 2
A thermal curing source is positioned at the second location and cures the compressed plurality of materials.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method and system for connecting a plurality of materials using pressure and curing is disclosed. The method provides for: a) receiving the plurality of materials on the vacuum conveyor; b) conveying the received plurality of materials from the first location to a second location along the vacuum conveyor; c) applying a predetermined vacuum pressure; and d) curing the compressed plurality of materials. The system comprises a vacuum conveyor for receiving the plurality of materials at a first location, a moving belt adaptively positioned above the vacuum conveyor at a second location and the vacuum conveyor and the moving belt are arranged to be driven in a predetermined relation to one another, a vacuum pressure source for applying a predetermined vacuum pressure creating a force compressing the plurality of materials; and a curing source at a second location for curing the compressed plurality of materials.