Vacuum Suction Unit for Stable Solar Cell and Solder Ribbon Transfer
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Solution Overview
Problem
Existing solar cell string manufacturing methods face inefficiencies due to complex bonding and layout processes, which can lead to hidden cracking and breaking of solar cells during transportation, and require precise positioning of solder ribbons, increasing costs.
Innovation Solution
A transfer mechanism using a conveyor belt with air-permeable zones and air holes to hold and fix solar cells and solder ribbons without external pressure, combined with a loading device for continuous film laying, ensuring stable positioning and conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression mechanism is used to fix solar cells and adhesive film onto conveyor belt during transportation, then fixing stability is improved, but solar cells are prone to hidden cracking and breaking
Solution Approach 1:
The patent uses a suction conveyor belt with vacuum holes to create negative pressure for holding solar cells and adhesive films. The vacuum suction mechanism replaces mechanical compression, providing secure fixation without applying excessive compressive forces that could cause hidden cracking or breaking of the solar cells.
Solution Approach 2:
The patent changes the pressure parameter from positive compression to negative pressure (vacuum suction). By creating a pressure difference through the vacuum holes in the conveyor belt, the system achieves reliable fixation while avoiding the harmful effects of mechanical compression on the solar cell structure.
2Manufacturing precision
If solder ribbon is pre-bonded with adhesive film before bonding to solar cells, then positioning accuracy is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent performs preliminary positioning of the solder ribbon on the adhesive film before solar cell bonding. The vacuum conveyor belt holds the pre-positioned solder ribbon and adhesive film assembly, ensuring accurate positioning is maintained throughout the bonding process without requiring complex repositioning mechanisms.
Solution Approach 2:
The patent combines the positioning and fixation functions into a single vacuum conveyor belt system. The same vacuum mechanism that holds the solar cell also secures the adhesive film and solder ribbon assembly, simplifying the overall bonding process while maintaining positioning accuracy.
3Strength
If complex bonding and layout process is used for solar cell string manufacturing, then bonding strength is improved, but production efficiency decreases
Solution Approach 1:
The patent enables continuous production by using the vacuum conveyor belt to maintain secure holding of solar cells, adhesive films, and solder ribbons throughout the entire bonding and layout process. This continuous secure fixation eliminates interruptions and allows the bonding process to proceed without repeated positioning or re-fixation steps.
Solution Approach 2:
The vacuum conveyor belt system provides self-positioning and self-fixation capabilities. Once the solar cell, adhesive film, and solder ribbon are placed on the conveyor belt, the vacuum automatically secures them in position without requiring additional external fixing mechanisms or manual adjustments during the bonding process.
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
Enhances production quality and efficiency by stabilizing solar cell and solder ribbon positioning during the laying process, reducing the risk of cracking and improving manufacturing throughput.
Implementation Method 1
a first negative pressure is formed between the channel S1 and a bottom surface of the solar cell (101), such that the solar cell (101) stacked on the solder ribbon (102) is held and fixed
Implementation Method 2
a second negative pressure is formed between the channel S2 and a bottom surface of the film (200, 104), so as to hold and fix the film (200, 104)
Data Source
Figure 1~3
Figure 4~6
Figure 7
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 S1 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.