Vertical Wafer Feeding and Inserting to Reduce Breakage
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Solution Overview
Problem
Conventional horizontal wafer-separation methods in photovoltaic silicon wafer manufacturing lead to high wafer breaking rates, increasing costs and space requirements.
Innovation Solution
A vertical feeding and wafer inserting integrated machine is developed, integrating a carrying-transferring water tank, feeding unit, wafer inserting unit, and washing manipulator, which uses a primary and secondary feeding mechanism to transition wafers from vertical to horizontal, reducing breakage through a controlled feeding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a horizontal wafer-separation method is used, then the wafer inserting process can be completed, but the wafer breaking rate increases
Solution Approach 1:
The patent inverts the conventional horizontal wafer separation method by implementing a vertical wafer separation approach. The feeding unit conveys wafers vertically from the water tank through the conveying belt to the inserting position, and the wafer basket moves vertically to receive wafers. This vertical configuration fundamentally changes the separation direction, reducing wafer breaking rates while maintaining inserting efficiency.
Solution Approach 2:
The patent transitions from horizontal wafer separation to vertical wafer separation by adding the vertical dimension to the conveying and inserting process. The conveying belt moves wafers in the vertical direction, and the wafer basket ascends vertically to receive wafers at different heights. This dimensional change optimizes the separating effect and reduces mechanical stress on wafers.
2Adaptability or versatility
If multiple separate machines are used for carrying, feeding, inserting, and washing, then each function can be optimized independently, but the device complexity and space requirements increase
Solution Approach 1:
The patent merges four separate functions (carrying, feeding, inserting, and washing) into a single integrated machine. The frame body houses the water tank, feeding unit with conveying belt, wafer inserting unit with basket, and washing manipulator all in one configuration. This integration reduces the number of independent machines from four to one, simplifying the overall system while maintaining all necessary functions.
Solution Approach 2:
The integrated machine performs multiple functions through coordinated components: the water tank carries wafers, the feeding unit conveys them vertically, the inserting unit places them in baskets, and the washing manipulator cleans the baskets. Each component serves its specific function while contributing to the overall multi-functional capability of the single machine system.
Data Source
AI summary
The present invention provides a vertical feeding and wafer inserting integrated machine, comprising a rack and a silicon wafer transfer device provided on the rack; a carrying-transporting water tank for carrying and transporting silicon wafers is provided on one end of the rack; the rack is further provided with a feeding unit for conveying the silicon wafers in the carrying-transporting water tank to a silicon wafer transfer belt a wafer inserting unit for inserting the silicon wafers into wafer baskets is provided on one end, away from the feeding unit, of the silicon wafer transfer device, and a wafer basket arraying mechanism is provided on the other end of the wafer inserting unit; and a washing manipulator for transferring grouped wafer baskets to a washing procedure is further correspondingly provided on the rack.