Vacuum Suction Unit for Crack-Free Solar Cell String Laying
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Solution Overview
Problem
The existing methods for manufacturing solar cell strings are inefficient due to the complex bonding and layout processes, which require high positioning accuracy and can lead to hidden cracking and breaking of solar cells during transportation, necessitating an improved transfer and fixing mechanism.
Innovation Solution
A suction unit and transfer mechanism that use air-permeable zones and negative pressure channels to securely hold and fix solar cells and solder ribbons on a conveyor belt without external pressure, allowing for stable positioning and conveyance during the laying of solar cell strings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If compression mechanism is used to fix solar cells and adhesive film onto conveyor belt, then positioning stability is improved, but solar cells are prone to hidden cracking and breaking
Solution Approach 1:
The patent uses a suction device with air holes and negative pressure channels to create vacuum suction that holds the solar cell string on the conveyor belt. This pneumatic fixing method replaces mechanical compression, providing stable positioning without applying excessive pressure that would cause hidden cracking or breaking of the solar cells.
Solution Approach 2:
The patent changes the fixing parameter from mechanical pressure to negative pressure (vacuum). By controlling the negative pressure level, the system achieves sufficient holding force for stable positioning while avoiding the high pressure that causes solar cell damage.
2Reliability
If complex bonding and layout process is used to bond solder ribbon with adhesive film, then bonding reliability is improved, but manufacturing efficiency is reduced
Solution Approach 1:
The patent performs preliminary bonding of the solder ribbon to the adhesive film before the laying process. This preliminary action ensures bonding reliability is established in advance, allowing the subsequent laying and transportation processes to proceed efficiently without requiring complex real-time bonding operations.
Solution Approach 2:
The patent combines multiple functions into the conveyor belt system: transportation, positioning, and fixed holding of the solar cell string. By merging these functions, the system eliminates the need for separate complex bonding and layout mechanisms, thereby improving manufacturing efficiency while maintaining reliability.
3Manufacturing precision
If external pressure is applied to fix solar cells during transportation, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent uses a pneumatic suction system integrated into the conveyor belt to achieve positioning and fixing. The air holes and negative pressure channels create a distributed suction field that provides accurate positioning without requiring complex mechanical pressure application devices or external fixing mechanisms.
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 solution enhances the efficiency and stability of solar cell string production by maintaining the position of solar cells and solder ribbons without external pressure, reducing the risk of cracking and improving the overall quality and efficiency of the manufacturing process.
Implementation Method 1
a first negative pressure is formed between the first channel and a bottom surface of the solar cell, such that the solar cell stacked on the solder ribbon is held and fixed
Implementation Method 2
an air-permeable zone is provided in a projection area of the solar cell on the film
Data Source
AI summary
A suction unit, including a first module, a second module, and a third module. The first module is provided with an air-permeable zone. The second module is provided with air holes a. The third module is provided with air holes b. A solder ribbon and a solar cell are sequentially stacked on the first module. A channel S2 is formed by the air holes b and the air holes a to fix the first module to the second module. A channel Si is formed by the air holes b, the air holes a and the air-permeable zone to fix the solder ribbon and the solar cell on the first module.