NL2018395B1 - Apparatus, assembly method and assembly line - Google Patents
Apparatus, assembly method and assembly line Download PDFInfo
- Publication number
- NL2018395B1 NL2018395B1 NL2018395A NL2018395A NL2018395B1 NL 2018395 B1 NL2018395 B1 NL 2018395B1 NL 2018395 A NL2018395 A NL 2018395A NL 2018395 A NL2018395 A NL 2018395A NL 2018395 B1 NL2018395 B1 NL 2018395B1
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- Prior art keywords
- solar cell
- contact
- carrier
- dispensing unit
- contact material
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0516—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module specially adapted for interconnection of back-contact solar cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/043—Mechanically stacked PV cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
- H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Abstract
In the assembly of solar panels, solar cells are place onto a carrier.The apparatus comprises holding means for holding a stack of solar cells to be assembled; a lifting unit comprises a pick-up means for picking up a solar cell from a top of said stack, said means being configured for contact with the upper, first side of said solar cell, further comprising means for movement of said pick-up means; a dispensing unit for dispensing droplets of contact material to contact pads on said second side of the solar cell; a support unit for said carrier, and a controller for controlling at least the lifting unit and the dispensing unit, so that all contact pads are provided with contact material. Herein, the contact material is applied from the bottom side.
Description
FIELD OF THE INVENTION
The invention relates to an apparatus for assembly of a plurality of solar cells to a carrier. The invention further relates to a method of assembly of a plurality of solar cells onto a carrier, which solar cells have a first side and an opposed second side, at which second side a plurality of contact pads are present.
The invention also relates to an assembly line for assembly of a solar panel comprising a carrier, a plurality of solar cells having contact pads at a second side thereof, via which the solar cells are electrically coupled to predefined contact pads on the carrier, and at least one encapsulant layer, which assembly line comprises a plurality of stations for carrying out one or more predefined steps in the assembly of the solar panel, and a movement means for moving at least one movable table carrying the carrier with any further assembled element or layer from a first station to a further station.
The invention moreover relates to the use of the assembly line for assembly of a solar panel.
BACKGROUND OF THE INVENTION
Solar panels comprise a plurality of solar cells, a carrier and encapsulating material for protection of the solar cells. Electrically conductive means, such as volumes of electrically conductive glue or solder are present between contact pads of the solar cells and corresponding contact pads on the carrier. The encapsulating material typically comprises an elastic material and a substantially rigid plate, for instance a glass plate as a cover. The elastic material fills any space between the said plate and the solar cells and around the solar cells, and further is in contact with the carrier.
The assembly of solar panels is suitably carried out with an assembly line which includes a plurality of stations of carrying out one or more steps in the assembly. One example of an assembly line is known from EP2510554B1 in the name of the current applicant. The known assembly line is particularly designed for so called back-contact solar cells. In such cells, all contact pads are present on a second side of the solar cell, which is opposed to a first main side intended for exposure to and receipt of sunlight, i.e. any solar radiation. Herein, there is a need for establishing contact between the solar cells and the contact pads on the carrier. The conductive material has a small size relative to the size of the solar panel, such that careful positioning of the carrier and the subsequently applied layers and elements to each other is needed. In fact, if one connection between a solar cell and the earner fails, the entire solar panel does not meet specifications and needs repair or must be rejected. According to the said patent, this accurate positioning is achieved by means of a movable table including vacuum means. The use of such movable table ensures that the layers and elements do not shift relatively to each other during transport from one station to a subsequent station.
In the known assembly method, spots or dots of electrically conductive adhesive are applied within holes in an insulating layer of encapsulant material present on the carrier. In a subsequent station, solar cells are provided. The solar cells are positioned such that the contact pads of the solar cell are brought in contact with the dots of adhesive. Subsequently, a further layer of encapsulant material and a glass plate are provided. After a first heating step to connect the layers, the stack may then be heated to liquefy the encapsulant material and ensure that the solar cells are fully protected.
Recently, there is a trend to reduce the thickness of solar cells. As a consequence, solar cells become even more fragile and there is an increased risk that the solar cells may crack or break during assembly. In the known method, it is not 100% sure that the adhesive on the carrier in the holes gets into contact with the contact pads of the solar cells upon placement of the solar cells. If the dot of adhesive has a height that is just below the height of the insulating layer, the solar cell will initially lay on the insulating layer. Only upon heating, the contact is then established. While this functions in itself adequately and even very well, there is a risk of cracking, particularly with a reduced thickness of solar cells, due to the pressure of the glass plate and under heating of the panel, wherein the different elements will expand differentially. Since the insulating layer is elastic, the solar cells are floating in this stage, and may slightly move, bend, rotate.
Therefore, there is a need for an improved assembly method that is also suitable for solar cells with a reduced thickness.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a method of assembling solar cells to a carrier, and an apparatus for carrying out the assembly of solar cells to a carrier.
Further objects relate to the provision of an assembly line and a method for the manufacture of a solar panel.
According to a first aspect, the invention provides an apparatus for assembly of a plurality of solar cells onto a carrier, which solar cells have a first side and an opposed second side, at which second side a plurality of contact pads are present, which apparatus comprises: (1) holding means for holding a stack of solar cells to be assembled; (2) a lifting unit comprises a pick-up means for picking up a solar cell from a top of said stack, said means being configured for contact with the upper, first side of said solar cell, further comprising means for movement of said pick-up means; (3) a dispensing unit for dispensing droplets of contact material to contact pads on said second side of the solar cell; (4) a support unit for said carrier, and (5) a controller for controlling at least the lifting unit and the dispensing unit. The controller is herein more particularly configured to control the performance of the method of the invention.
According to a second aspect, the invention provides a method of assembly of a plurality of solar cells onto a carrier, which solar cells have a first side and an opposed second side, at which second side a plurality of contact pads are present, comprising the steps of:
picking up a first solar cell from a stack of solar cells to be assembled, while contact is made with the first side of the solar cell;
moving the first solar cell and/or a dispensing unit, such that the dispensing unit can dispense a first volume of said contact material on a first contact pad on a second side of the solar cell, and without turning the first solar cell upside down;
dispensing the first volume of said contact material on said first contact pad;
repetitively effecting displacement of the first solar cell relative to the dispensing unit and dispensing a further volume of contact material onto a further contact pad, until a predefined set of contact pads have been provided with contact material;
moving the first solar cell to a predefined location on the carrier, and disposing the first solar cell onto the carrier at the predefined location, wherein the pick-up means are removed from the solar cell, and repeating the preceding steps for a further solar cell from the stack of solar cells, until a predefined number of the solar cells is disposed onto predefined locations on the carrier.
According to a third aspect, the invention relates to an assembly line for assembly of a solar panel comprising a carrier, a plurality of solar cells having contact pads at a second side thereof, via which the solar cells are electrically coupled to predefined contact pads on the carrier, and at least one encapsulant layer, which assembly line comprises a plurality of stations for carrying out one or more predefined steps in the assembly of the solar panel, and a movement means for moving at least one movable table carrying the carrier with any further assembled element or layer from a first station to a further station, wherein the apparatus of the invention is present as one of the stations.
According to a fourth aspect, the invention relates to a method of manufacturing a solar panel, comprising the step of assembling a plurality of solar cells to a carrier according to the invention, wherein more particularly the assembly line of the invention is used.
The invention starts with the insight, that when applying dots or bumps of contact material on the solar cells rather than on the carrier, these dots or bumps will have a mechanical function to support the solar cells during the assembly. The dots or bumps are sufficiently elastic to absorb pressure from above. Because of the presence of a plurality of bumps or dots, it is prevented that the solar cell with bend through on one side, with an increased risk of cracking. However, the application of dots or bumps on the solar cells presents further engineering problems. While adhesive material may be applied on the carrier by means of screen printing or another large-area deposition technique, the application of contact material on the solar cell does not allow this type of application. It would require the provision of a mask that needs to be removed thereafter. And the provision of individual dots or bumps may be slower than acceptable to achieve a commercially demanded throughput. According to the invention, this speed limitation is overcome, or at least reduced in that the bumps or dots are applied from the bottom side, thus upwards. This eliminates the need to turn the solar cell. This essentially means that the solar cell is once picked up by the lifting up, then provided with the volumes of contact material and immediately thereafter disposed on the carrier.
In one preferred embodiment, the dispensing unit is provided with nozzle configured for dispensing said droplets of said contact material. Such a dispensing unit is also known as an inkjet printer, which are available as continuous inkjet printers and drop-on-demand type inkjet printers. The drop-on-demand type inkjet printers are preferred in the context of the invention. More preferably, use is made of piezoelectric actuator or an electromagnetic valve jet, as known per se in the art. In one implementation, the droplets are ejected from the nozzle and accelerated towards the contact pad, in an upwards direction. In another implementation, droplets are formed on the printing nozzle. The solar cell may then be moved towards the dispensing unit, so as to transfer the droplet onto the contact pad. In one embodiment, the dispensing unit is configurable to operate in both modes, i.e. by ejecting droplets and by forming droplets on top of the nozzle. This is particularly arranged by means of the voltage applied to the actuator, i.e. the piezoelectric actuator or the valve coil of the valve jet. Optionally, a droplet holding means may be present at the nozzle, for instance in the form of a needle or a curved surface.
In one embodiment, the droplets of contact material are not merely applied on the surface, but ejected, typically with a predefined speed, to the relevant contact pad. It is deemed surprising that the adhesion of the volumes of contact material to the contact pad is appropriate. When applying material that is at least partially in liquid form, there is on the one hand the possibility that the liquid will just wet the surface and spread out. The volume would no longer have the shape to bridge the distance between the solar cell and the carrier; rather, a risk of short-circuiting is present. On the other hand, the liquid may fall off the contact pad, particularly in view thereof, that according to the invention, the dots or bumps will hang down from the contact pads of the solar cell. The inventors have observed experimentally that both situations do not occur. Conductive adhesive as commercially available, such as based on an epoxy, an imide or a silicone resin and filled with metal particles can be ejected with suitable speed to adhere to the contact pads of the solar cell. This also applies when the droplets are ejected upwards. The conductive adhesive may contain a separate carrier liquid such as an acrylate or a keton, for instance ethylacetate or methylethylketon. Alternatively, the resin component or at least some parts thereof are in liquid form. The carrier liquid is in then a reactive component. The latter is deemed particularly suitable, so as to prevent that carrier liquid would end up within the solar panel.
In a preferred implementation, the nozzle is configured for dispensing droplets with a droplet diameter between 50 and 500 pm, for instance in the range of 100-300 pm, such as 150-250 pm. Furthermore, in order to create larger droplets on the contact pad of the solar cell, more than one droplet may be dispensed. In this manner, volumes with a diameter in the millimeter range, for instance up to 2 mm, may be created.
In again a further implementation, the apparatus is configured for printing volumes according to predefined shapes, such as for instance lines, including curved lines, rings, and/or larger surface areas. This may be effected by subsequently dispensing droplets, while simultaneously and/or intermittently moving the solar cell relative to the dispensing unit.
In one implementation, the adhesive material may be conditioned prior to dispensing so as to have a predefined temperature, for instance in the range of 20 to 100°C, such as 30 to 60°C. This is deemed beneficial for several reasons. First of all, the temperature increase will decrease the viscosity, but since the droplet is subsequently exposed to the ambient environment, typically room temperature, this decrease is merely temporary. The viscosity can thus be steered so as to ensure a proper dispensing, and therewith reducing the risk of clogging. At the same time, the subsequent viscosity increase provides the droplet with additional resistance against falling off from the contact pad. Secondly, the higher temperature may initiate a further polymerisation reaction within the resin, which leads to higher molecular weight and therewith to higher viscosity. It is deemed that the polymerisation reaction will not be completely finished herein, but at least the average molecular weight may increase. The viscosity of the contact material may be chosen in a relatively wide range, for instance in the range of 0.1-40.000 Pas, more preferably 100-10.000 Pas, for instance 500-5000 Pas.
In a further implementation, the nozzle is placed at a distance of 0.2 to 5 mm from the contact pad, more preferably in the range of 1-3 mm, such as 1.5-2.5 mm. Such a distance was found to be suitable for a proper ejection from the nozzle to the contact pad, but also suitable for the arrangement the solar cell relative to the dispensing unit in an appropriate speed.
Suitably, the dispensing unit is provided with movement means, and wherein the relative displacement of dispensing unit and the first solar cell involves movement of the movement means of the dispensing unit and of the lifting unit. This configuration allows that both the dispensing unit and the solar cell can be moved relative to each other. Since the time needed for the provision of the volumes of contact material depends for a large part on the time needed for the relative movement and accurate positioning, a combined movement accelerates the process. Particularly, it is foreseen, that the movement means are configured for movement in two different directions, such as two perpendicular directions.
In one specific embodiment, the apparatus is provided with a second dispensing unit such a volumes of contact material can be applied to a first and a second contact pad in a single dispensing period between a first and second displacement period in which at least one of the first solar cell and the dispensing units are is displaced relatively to each other. By doubling the amount of the dispensing units, the overall processing time reduces accordingly. The double dispensing is particularly feasible, since contact pads of a solar cell are typically provided in a regular pattern. It is thus feasible to move the first solar cell relative to the first and second dispensing unit, such that after a single movement both dispensing unit are again properly located to dispense a volume of contact material, suitably a bump or dot or a plurality of dots.
As an alternative to increasing the number of dispensing units, a single dispensing unit may comprise a plurality of printing heads each including a nozzle and a corresponding actuator, such as piezoelectric actuators or electromechanical actuating means, such as a valve coil in a valve jet. This simplifies the location process, and therewith increases the speed of printing. The individual nozzles may have a fixed position within the dispensing unit or could be movable in a single direction, for instance along a rail.
Rather or in addition to the use of a second dispensing unit, the printing head may further be rotatable, such that a single dispensing unit may dispense volumes of contact material to more than one contact pad. A rotation of printing head is less time-consuming that a translational movement.
In a further embodiment, the dispensing unit is provided with a means for orientation of the printing head, such that the nozzle can be configured for ejecting a volume of contact material in an oblique angle relative to the second side of the solar cell. Herewith the incident angle between the volume of contact material and the contact pad is reduced, in comparison to an orientation wherein the nozzle is located perpendicular to the second side of the solar cell. The lower incident angle has the benefit that the contact time and typically also the contact area between the volume and the contact pad increases, which facilitates adhesion of the volume to the contact pad.
In one specific implementation, the means of movement of the lifting unit is configured for movement of the solar cell along a first displacement line running in parallel with a direction of an ejected volume of contact material. This is deemed beneficial for the organisation and control of the dispensing. Moreover, it becomes easy to integrate a sensor into the dispensing unit, so as to verify the position of the contact pad, prior to the dispensing of a volume. Even though the position of the contact pad is typically known in advance, the integration of an optical sensor such as a camera, prevents faulty dispensing. Such faulty dispensing could occur because one of the solar cells in the stack is laid down differently, i.e. rotated relatively to other ones of the stack.
In one further implementation hereof, the controller is configured for effecting dispensing of a volume of contact material while the first solar cell moves along the first displacement line. Hence, the ejection of the droplet of contact material in a direction parallel to the movement direction of the first solar cell enables that the droplet may be ejected before the first solar cell is stopped entirely. It is even feasible that the first solar cell is not stopped at all, but that the droplet of contact material hits the contact pad while the solar cell moves. Since the direction of movement of the volume of contact material is - in a plane parallel to the second side of the solar cell - the same as the movement of the first solar cell, the continuous movement of the latter merely implies that the relative speed of the droplet of contact material is reduced.
In again a further embodiment, the support unit comprises a movable table configured for the application of a carrier and a frame provided with movement means, wherein both the movable table and the frame comprise positioning means, such that upon movement of the movable table in a predefined position, the movable table is positioned by matching of the positioning means in the movable table and the frame. In this embodiment, the through-put of the apparatus is further increased by means of an efficient exchange of the carrier. Most suitably, the movable table comprises vacuum means, such that the relative positioning of the different elements and layers on the carrier is maintained also during transport from one station to a subsequent station. Such vacuum means are for instance based on a venturi device, such as specified in EP2182549, which is included herein by reference.
Preferably, the movable table is configured for movement between a first and a second position in the said apparatus. This allows that the solar cells may be disposed significantly without a need for movement of the lifting unit in a direction parallel to the movement direction of the movable table. It is the movable table that moves stepwise, so as to allow a disposal of solar cells on the carrier row by row, and wherein each disposal occurs in substantially the same longitudinal position along the axis of movement of the movable table. In order to implement such stepwise movement of the movable table, the movable table is suitably provided with a plurality of positioning means matching positioning means of the frame. More particularly, the frame would have a single set or optionally a double set of positioning means, which is repeatedly used for the sequential positioning in the different positions of the movable table within the apparatus.
In a further embodiment, the apparatus is further configured for the provision of volumes of contact material on the carrier. It is observed that it is not necessary that the composition and volume of contact material on the carrier corresponds to that applied on the contact pads of the solar cells. Thereto, the apparatus suitably comprises a further dispensing unit, with an printing head. It could be that the volumes of contact material are herein simply dropped onto the relevant contact pads. Alternatively, they may be ejected according to a predefined orientation. The first option may be most adequate in view thereof that the carrier is typically protected with an insulating layer having holes that expose contact pads on the carrier. In the embodiment wherein the volumes of contact material are dropped, the printing head and/or nozzle does not need to be identical to that used for the provision of volumes, more particularly dots or bumps to the contact pads of the solar cell. Furthermore, it may be suitable that the volume applied to the contact pads of the carrier forms a layer rather than a bump- or droplet-shaped volume. An advantage of this embodiment is that the dispensing of volumes of contact material on the carrier and on the solar cell may be carried out simultaneously, so as to reduce time loss. Furthermore, this embodiment allows the use of relatively small bump- or droplet-shaped volumes to the contact pads of the solar cell. Such small volumes may be desired in view of shrinking dimensions of the contact pads, and in order to reduce consumption of contact material. However, with shrinking dimensions of the bumps, the height of the bump-or droplet-shaped volumes also reduces, and therewith the effective distance between the carrier and the solar cell. Such reduced dimensions typically lead to an increase in stress during the lifetime, particularly in view of the differential expansion of the solar cells, usually based on a silicon substrate, and the carrier, usually based on an epoxy-resin or another polymer material.
In again a further embodiment, the apparatus may be further configured for the provision of volumes of contact materials on auxiliary components. Examples of such auxiliary components may be electronic circuits for driving and control of the solar panel, capacitors and batteries suitable for the storage of electric charge, bypass and protection devices and the like. The electronic circuits may be provided in the form of one or more integrated circuits, but alternatively be circuits defined on a circuit board and containing a plurality of components.
It is observed, for sake of clarity, that the method of the invention is suitably carried out with the apparatus of the invention. Any embodiment presented hereinabove and/or in the claims with respect to one aspect, is also applicable and deemed disclosed with respect to another aspect of the invention.
BRIEF INTRODUCTION OF THE FIGURES
These and other aspects of the invention will be further elucidated relative to the figures, wherein: Fig. la-ld diagrammatically show four stages in the process of the invention.
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
The figures are not drawn to scale and identical reference numerals in different figures refer to equal or corresponding parts.
Fig. 1 a-d diagrammatically show four stages in the process according to a first embodiment of the invention. Shown in Fig. la is a stack 110 of solar cells 10. The stack 110 is provided such that the solar cells 10 are provided with their top side 1 upwards and their bottom side 2 downwards (the sides 1, 2 have been indicated in Fig. lb). The stack 110 of solar cells 10 is usually present on a carrier, which is not shown in the present illustration. Furthermore, a lifting unit 50, hereinafter also referred to as robot 50 is shown. The lifting unit 50 is provided with pick up means 51 for attachment to and picking up of a solar cell 10. This illustration is highly schematical. Typically, the pick up means 51 will operate on the basis of underpressure. Such underpressure may be applied by underpressure means arranged in or on the lifting unit 50. While the Figure la specifically shows two pick up means 51, this is for the sake of illustration. However, it may be useful to provide several attachment areas distributed over the solar cell 10. Alternatively, according to a preferred implementation (not shown), the pick up means comprise a distribution layer provided with channels and/or pores through which the underpressure will be distributed over a first surface area. The first surface area is for instance at least 50%, and preferably at least 70% of the surface area of a single side 1, 2 of the solar cell 10. It is for sake of clarity observed that the first side 1 of the solar cell 10 is typically provided with a textured surface. The texturing is not taken into account in the above mentioned preferred minimum surface area of the first surface area. Additionally, the pick up means 51 may be provided with a flexible contact layer for contact to the first surface of the solar cell. The flexibility and more particularly elasticity of this contact layer can be exploited to prevent damage to the first side of the solar cell. Such damage, for instance in the form of scratches, would reduce the efficiency of the solar cell.
The lifting unit 50 is typically provided with arms that can be extended, for instance through the use of a pressure cylinder, and with means for rotation. Also the robot is suitably attached to a rail or frame in a movable manner, so as to carry out a movement in at least one direction, and suitably two orthogonal directions. Furthermore, Figure la shows a printing means 80.
Fig. lb demonstrates that the lifting unit 50 picks up a first solar cell 10 from the stack 110 of solar cells. As shown herein, the pick-up means 51 are applied to be in contact with the first side 1 of the solar cell 10. The second side 2 is not touched. Preferably, air is applied into a space between the first solar cell 10 and an underlying further solar cell. This air or other gas is intended to create some overpressure. As a consequence, the first solar cell will start to float on the air layer. This has the effect, that any further solar cell will not be attracted by the underpressure exerted by means of the pick up means 51 of the lifting unit 50. In a further implementation, not shown, the holding means of the stack of solar cells is provided with a support. The support is configured for carrying the stack of solar cells, and is preferably configured such that its vertical position can be varied. Particularly, the support is to be brought to a higher position so as to arrange that the upper solar cell of the stack remains at a predefined height.
This second side 2 of the solar cell 10 is configured for assembly to a carrier 11, as shown in Fig. Id. Thereto contact pads are present on the second side 2 of the solar cell 10. This particularly applies to solar cells 10 with back-side contacts, for instance solar cells 10 of the MWT-type (metal wrap through) and of the IBC-type (interdigitated back contacts). However, the shown method is in principle also suitable for solar cells in which first contacts are present on the first side 1 and second contacts are present on the second side 2. For such solar cells 10, the method is for instance extended in that the contacts on the first side 1 are mutually connected to form a string and are further connected to appropriate contacts on the carrier 11. Use is for instance made of socalled bus bars.
Fig. lc demonstrates movement of the solar cell 10 towards the dispensing unit 80. The dispensing unit 80 typically contains one or more printing head having nozzles. Typically, the dispensing unit is based on ink jet. The dispensing unit 80 is further provided with a container of conductive material. As known to those in the art, the dispensing unit 80 for inkjet is furthermore provided with an actuator, known per se, for instance piezoelectric actuator, an acoustic actuator, a thermal actuator, or any actuator based on electromagnetic actuation such as in a valve jet. The dispensing unit 80 will operate to print conductive material onto the contacts on the second side 2 of the solar cell, while being stabilized by the lifting unit 50. Preferably, the dispensing unit is furthermore provided with temperature conditioning means, which are more particularly embodied as a heater. This is done as the viscosity of a material strongly depends on the temperature, which is very strongly the case for polymeric material. When printing upwards, it is to be prevented that the material would not form droplets but remain present as a column. Therefore, it is preferred to heat the conductive material to a predefined temperature. The temperature will be dependent on the specific material and may be specified by a user by means of a user interface. It is furthermore deemed advantageous that the dispensing unit comprises a temperature sensor, for instance located in the container.
While the dispensing unit 80 is shown in highly schematically manner, it is observed that the dispensing unit 80 may contain more than a single nozzle. For instance a first and a second nozzle can be present. The number of nozzle within a single dispensing unit can also be larger than 2, for instance 3 or 4 or 5. It may be embodied as a multiple of nozzles within a single printing head, or as a plurality of printing heads. The integration of several nozzles in a single dispensing unit is understood to be beneficial not merely for the overall speed of the apparatus, but also to minimize driving complexity. The nozzles within a row can be moved with a single movement means attached to the dispensing unit. The individual nozzles may have a predefined position or may be movable in a limited manner, for instance along a line, implementable as a movable contact on a rail or shaft. The dispensing unit comprises in one embodiment a single container of conductive material for all of the nozzles. More precisely, different embodiments are foreseen. In a first embodiment, a first and a second nozzle are present so as to facilitate that more than one single droplet is dispensed towards a single contact pad. In this embodiment, it is deemed most suitable that the first and the second nozzle are part of a single printing head. However, the first and second nozzle may also be part of different printing heads. In a second embodiment, a first and a second nozzle are present so as to facilitate efficient dispensing of droplets of contact material on different contact pads, typically adjacent contact pads. In this embodiment, it is deemed suitable that the first and second nozzle are part of different printing heads.
The conductive material, for instance an electrically conductive glue, is applied from the printing means with a sufficient velocity. Such electrically conductive glues are known per se and contain an adhesive material, for instance based on epoxy, acrylate or silicone, and conductive particles, for instance of silver, aluminium-silver, tin-silver or a metal with a silver coating. Alternatively, use may be made of a solder paste, more preferably a solder paste with a relatively low melting point, such that an electrically conductive connection will be made during a heating step of the final panel. Such heating step is typically arranged to ensure liquefying and curing of the encapsulant. Typically, the printing means eject droplet after droplet. Suitably, the printing means are provided with a movement means, for movement of the printing means along at least one direction, and possibly two directions. It is deemed suitable for the overall speed that the dispensing unit move in one direction, while the robot moved in a second direction, to minimize the time between individual printing moments. More precisely, the movement of the dispensing unit will be controlled by means of a controller and the printing locations will be specified using the information obtained from a digital camera and analysed by means of a processor. In fact, the position of a specific contact pad will not be the same for any of the solar cells in the stack, for at least two reasons. First of all, due to the provision of air below an upper solar cell to render it floating, the lateral position of the solar cell may slightly vary. Secondly, the manufacture of the contact pads on the solar cell is typically done by screenprinting of a metal paste. As a consequence, inter-individual variation of the location of some contacts may occur. The positioning of the nozzle, more particularly the printing head comprising the nozzle, of the dispensing unit has to be adapted. Particularly, when a first volume of conductive material would be printed not within but slightly outside a contact pad, the adhesion of the conductive material to the solar cell may be affected negatively; the metallic contact pad will have a different hydrophobicity than an adjacent surface, which results in differences with respect to the contact angle. Moreover, a deviation of the printing location may lead to a mismatch with any contact pads on the carrier.
The printing of droplets onto a second, bottom side of the solar cell 10 results therein that the conductive material will hang down from the solar cell. This situation is understood to be beneficial, as it minimizes the effective lateral spreading of the droplet, which may occur when applying conductive material on a top side of the carrier. As such, this method will lead to a reduction of the consumption of the conductive material. Such a reduced consumption is deemed advantageous, as silver-filled conductive glue constitutes a significant portion of the overall assembly costs. An additional advantage of printing at an elevated temperature, i.e. above room temperature is that the droplet may cool down after its printing, due to the lower temperature of the solar cell and the air. As a consequence, the viscosity of the droplet will increase, which reduces the risk that individual droplets would fall off the solar cell. While not shown, an inspection means, such as by means of optical inspection, may be present and verify correct disposal of the conductive material on the contact pads on the second side 2. Rather than one dispensing unit as illustrated, a plurality of dispensing units 80 may be present.
Fig. Id demonstrates assembly of the solar cell 10 to the carrier 11. The carrier 11 typically includes a conductive sheet. An insulating top layer 12 is present thereon. Suitably, the insulating top layer 12 is provided in a patterned manner, so as to be absent in areas corresponding to underlying contact pads. Optionally, a layer of conductive adhesive or solder may be present on contact pads of the carrier 11. The robot 50 is moved in such a manner so as to place the solar cell 10 in the correct and predefined location. In one preferred embodiment, the carrier 11 is thereto positioned relative to a frame to which the robot 50 is connected. A preferred way of positioning is known from EP2701207A1 that is included herein by reference. Herein the carrier 11 is applied on a mobile table. Thereafter, the mobile table with the carrier is moved to a station in which the solar cells 10 are assembled to the carrier, possibly after the provision of an intermediate insulating layer that is provided with predefined holes. In order to position to the mobile table to the frame of the station, a positioning means is used in the form of pins and cavities of matching form and location.
Rather than assembling the solar cells directly on the carrier, an interposer substrate may be used. Such an interposer substrate, as known per se from the field of integrated circuits, allows increase of dimensions of the connections step-wise. In such a case, one or more solar cells 10 are applied onto an interposer substrate after step lc. The interposer substrate is thereafter applied to the carrier
11. Further conductive material would be applied either on the bottom side of the interposer, or on the contact pads of the carrier 11, or on both.
Further steps in the assembly are suitably carried out in different stations in a single assembly line, such as the application of conductive material on the first side 1 of the assembled solar cells 10, in the event that solar cells 10 would have contacts on the first side 1, as well as the connection to the carrier 11; the provision of a further layer of insulating, encapsulant material, such as a material that liquefies at a relatively low temperature. The well-known example of such encapsulant material in solar cells is ethylene-vinyl acetate, also known as EVA. Furthermore, a glass plate may be applied on top, and after a preliminary heating stage, the assembly may be turned upside down, and be heated in a furnace, so as that liquefied encapsulant will fill any holes in the assembly and thereafter be cross-linked and thus stabilized.
Thus, in summary, the invention provides an apparatus for assembly of solar panels. In the assembly of solar panels, solar cells are place onto a carrier. The apparatus comprises holding means for holding a stack of solar cells to be assembled; a lifting unit comprises a pick-up means for picking up a solar cell from a top of said stack, said means being configured for contact with the upper, first side of said solar cell, further comprising means for movement of said pick-up means; a dispensing unit for dispensing droplets of contact material to contact pads on said second side of the solar cell; a support unit for said carrier, and a controller for controlling at least the lifting unit and the dispensing unit, so that all contact pads are provided with contact material. Herein, the contact material is applied from the bottom side. The apparatus may be integrated into an assembly line comprising a plurality of treatment stations.
Claims (30)
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NL2018395A NL2018395B1 (en) | 2017-02-20 | 2017-02-20 | Apparatus, assembly method and assembly line |
CN201810154239.2A CN108470790B (en) | 2017-02-20 | 2018-02-22 | Apparatus for mounting a plurality of solar cells on a carrier, and assembly line and method therefor |
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JP5716197B2 (en) * | 2011-10-21 | 2015-05-13 | スフェラーパワー株式会社 | Functional yarn with semiconductor functional element and manufacturing method thereof |
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EP2244308A1 (en) * | 2008-01-31 | 2010-10-27 | Sharp Kabushiki Kaisha | Method for manufacturing solar battery module |
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