DE102010027516A1 - Apparatus for high-precision structuring of the thin film solar cell modules, comprises a transport device for receiving and transporting a thin film solar cell module to a process unit in a transport direction, and a track detection unit - Google Patents

Abstract

The apparatus for high-precision structuring of the thin film solar cell modules, comprises a transport device (2) to receive and transport a thin film solar cell module (1) to a process unit (12) in a transport direction vertical to the width of the incorporated thin film solar cell module, where the process unit has structuring tools (3) and holders (4) movable on a rail vertical to the transport direction and controllable independent of each other, and a track detection unit for detecting and storing the track curves and the position of already introduced track, and a track control unit. The apparatus for high-precision structuring of the thin film solar cell modules, comprises a transport device (2) for receiving and transporting a thin film solar cell module (1) to a process unit (12) in a transport direction vertical to the width of the incorporated thin film solar cell module, where the process unit has structuring tools (3) and holders (4) movable on a rail vertical to the transport direction and controllable independent of each other, and a track detection unit for detecting and storing the track curves and the position of already introduced track, and a track control unit, with which linear drives present independent of the stored information are controlled, where the track control unit is connected with one holder. Each holder exactly carries a structuring tool, which moves the rail to a main rail that is parallelly arranged to the rail vertical to the transport direction. An additional main linear drive is present in connection with the rail to displace the rail along the main rail over the width of the incorporated thin film solar cell module. The linear drives have a common passive part, which is formed as magnet path along the rail. One of the structuring tools is a reference structuring tool, which is fixedly connected with the rail over the holder arranged to it.

Description

The invention relates to a device for structuring thin-film solar cell modules, as generically from the DE 10 2006 051 555 B3 is known.

Thin film solar cell modules consist of a rigid or flexible substrate which serves as a support for thin functional layers applied thereon.

In order to produce thin-film solar cell modules, after the planar application of a first functional layer to the substrate, it is typically removed linearly at predetermined distances from one another, whereby p1 traces having a depth equal to the thickness of the first functional layer are formed.

Subsequently, a second functional layer is applied flat, with which the p1-traces are filled. As close as possible to the p1 tracks, parallel p2 tracks are generated for this, in which the second functional layer, but not the first functional layer, is removed. After the planar application of a third functional layer, which fills the p2 tracks, so-called p3 traces are generated near the p2 tracks and the p1 tracks, in which the second and third functional layer, but not the first functional layer, is removed.

Mutually adjacent p1, p2, and p3 traces, which lie adjacent to each other in different processing planes, together form a transition region which separates the individual functional regions of the thin-film solar cell module.

For the introduction of the tracks different technologies are known, which can be based on mechanical, chemical or thermal effects. In this case, the tracks within a transition region, without overlapping or even crossing, have the smallest possible distance from each other to make the transition areas as narrow as possible.

Regardless of the technology of introducing the tracks, the substrate is subjected to thermal stress at least when applying the functional layers, which can lead to its deformation and thus to the deformation of already introduced tracks.

For this reason, at fixed track pitches, the size of the spacing of adjacent tracks toward the bottom has a limit that ensures that the tracks in the different layer planes do not overlap or intersect despite maximum possible deformation.

An arrangement with the same time several parallel tracks z. B. can be introduced into wafers, is from the DE 198 40 936 B4 known. The arrangement has a table for receiving z. As a wafer and at least two fiber lasers (structuring tools) with end pieces, which are arranged on a rail so that the mutual distance of the end pieces, which determines the track pitch, is variable. Under variable distances are here beyond doubt only outside the operation of the arrangement variably adjustable distances between the scoring tools meant. In order to realize the necessary relative to the generation of the tracks relative movement between the rail and the table, the table and / or the rail can be moved at least in one direction. By the rail or the table is also rotatable about an axis, the track spacing can be reduced without the distances of the scoring tools are changed.

When using this arrangement for introducing tracks in thin-film solar cell modules, it is disadvantageous that it is not suitable to observe track pitch variations of already generated tracks in the generation of further tracks, so the transition areas must be chosen so broad that these track pitch variations do not overlap leads from adjacent tracks.

In a conventional alignment of the tracks on the basis of an outer edge of a thin-film solar cell module therefore safety distances of about 100-200 microns for the desired course of the tracks are given to each other. That is, the patterning tool is guided for the tracks within a transition region with distances parallel to the outer edge, which differ from each other depending on the track width by about 100-200 microns. This creates a minimum width for a transition region of greater than 200-400 microns.

In order to provide a thin film solar cell module with narrower transition regions and thus improved efficiency, the DE 10 2006 051 555 B4 proposed to determine the course of already existing tracks before introducing further tracks and to regulate their course relative to the course of the existing tracks when introducing the further tracks. It is assumed that the tracks of juxtaposed tracks (here, tracks in one processing plane and non-adjacent tracks, all of which are generated in different processing planes) are approximately the same, and the track course of tracks further apart varies. Following this reasoning, the trace groups are formed, the distances of which are changed during the structuring process to each other, whereby more tracks are each generated in a group of tracks whose lane tracks at least come close to the lane course of the adjacent, already existing track group. The transition areas can thus be designed narrower.

Same as in the DE 10 2006 051 555 B3 recognized problem to be solved should be kept as low as possible with a device according to the invention, the distance of a transition region forming structuring lines (tracks) to make the transition region that provides no contribution to energy production by the thin film solar cell module, minimal.

In the DE 10 2006 051 555 B4 There is also proposed a suitable structuring device with which tracks can be produced as described.

Such a structuring device has a track detection unit with a camera, with which previously introduced and thus existing tracks are detected with regard to their track course and their position. With an image processing unit connected downstream of the camera, the recorded digital image showing the tracks is evaluated by per se known pattern recognition method (eg edge detection method). The evaluated information, in particular the distances that are varying along the track courses of different track groups relative to one another or to the first track group (reference group) in each case, are stored in a memory unit of the track detection unit.

The stored information is then supplied to a tracking control unit connected to the track detection unit, which controls the introduction of further tracks in groups.

Furthermore, a structuring device according to the DE 10 2006 051 555 B4 a transport device, for. As an air cushion table, for receiving and transporting the thin-film solar cell module to be processed. The transport takes place in a transport direction relative to a process unit which has a plurality of structuring units which can be controlled independently of one another perpendicular to the transport direction, wherein each structuring unit comprises at least two structuring tools fixed to one another at a fixed distance.

The structuring units are each suspended with a movable support on a rail arranged transversely to the transport device and are thus arranged spaced apart along the rail axis in a row. Each holder is provided with a drive which is controlled by the tracking control unit.

The structuring tools can, for. B. be mechanical scoring needles.

It will be apparent to those skilled in the art that a device according to the DE 10 2006 051 555 B4 advantageous compared to an arrangement according to the DE 198 40 936 B4 is because thin film solar cell modules can be realized with narrower transition areas and thus with a higher efficiency.

The revelation of DE 198 40 936 B4 allows the assumption that the process unit carries as many structuring tools as to create tracks over the entire width of the thin-film solar cell module. By combining the structuring tools in individual structuring units only so many drives, movable brackets, etc. are needed, as structuring units are available. However, the fewer structuring units are present, the more structuring tools must be provided per structuring unit, and thus the greater the deviations of the tracks of the other tracks from the already introduced tracks, since all structuring tools of a structuring unit are controlled jointly.

It is the object of the invention to propose a device for structuring thin-film solar cell modules, with which, without increasing the technical complexity of the device, the further tracks are generated with track curves, which are more precisely tuned to the tracks of already introduced tracks.

The object is for a device for highly accurate structuring of thin film solar cell modules with a transport device for receiving and transporting a thin film solar cell module in a transport direction perpendicular to the width of a recorded thin film solar cell module, a process unit, the plurality of structuring tools and on a rail perpendicular to the transport direction independently controllable movable Has holders, and a track detection unit for detecting and storing the track characteristics and the location of already introduced tracks and a tracking control unit, with the existing depending on the stored information linear actuators are triggered, each of which is in connection with a holder, achieved in that each holder carries exactly one structuring tool, the rail is movable on a parallel to this arranged main rail perpendicular to the transport device and an additional associated with the rail main Linear drive is available to move the rail across the width of a recorded thin film solar cell module along the main rail can.

Advantageously, the linear drives on a common passive part, which is designed as a magnetic path along the rail.

Furthermore, it is advantageous if one of the structuring tools is a reference structuring tool, which is advantageously fixedly connected to the rail via the holder assigned to it.

Reference to the drawing, the device will be explained in more detail below by way of example.

Show it:

1 a schematic diagram of a device according to the invention

A device according to the invention, shown in FIG 1 , essentially comprises a transport device 2 for receiving and transporting a thin-film solar cell module 1 , a track detection unit 6 , a tracking control unit 8th and a process unit 12 with structuring tools 3 ,

Even if the workpiece is not yet a finished thin-film solar cell module 1 but a substrate in various coating states, the term thin film solar cell module is used here to not use different terms for one and the same workpiece depending on the manufacturing state.

The transport device 2 does not differ from generically identical facilities. It consists essentially of a linear guide system and a tool table, which as a slide in the linear guide system in the x-direction, which represents the transport direction, via a linear drive 9 is movable.

By means of the transport device 2 can be on the tool table advantageous by means of vacuum voltage-fixed thin-film solar cell module 1 in the x-direction, in which the longitudinal edge of the thin-film solar cell module 1 aligned with a process unit 12 , at which the structuring tools 3 , in the z direction directed to the thin film solar cell module, are transported.

The transport device 2 is shown in the drawing only through the tool table.

The execution of the process unit 12 that are above the transport device 2 is arranged differs from the process unit known from the prior art in a manner essential to the invention.

With the terms of DE 198 40 936 B4 described, it includes a variety of brackets 4 , each a structuring tool 3 wear and on a rail 5 in y-direction, perpendicular to the transport device 2 , movably mounted, being the rail 5 itself, like a sled, on an existing main rail 10 also in the y-direction and thus across the width of one of the transport device 2 received thin-film solar cell module 1 can be offset.

The main rail 10 is part of a main guidance system and serves the common movement of all structuring tools 3 while the rail 5 Part of a guidance system integrated into the main guidance system is the relative motion of the structuring tools 3 to a selected reference structuring tool 3.1 and thus influencing the track course of the individual tracks 7 serves.

The reference structuring tool 3.1 can at the rail 5 firmly mounted or also be movably mounted on this. This results in differences in the control of the drives 9 . 11 the process unit 12 ,

Like the prior art is a track detection unit 6 with a camera, with the already introduced in a previous process step tracks 7 can be detected with their position and track course. The detected information becomes the tracking control unit 8th provided with the individual drives 9 . 11 the process unit 12 communicates.

The integrated guide system includes a variety of brackets 4 , each a structuring tool 3 wear. Either all structuring tools 3 or all except the reference structuring tool 3.1 , are each about a linear actuator 9 along the rail 5 movable. Advantageously, the linear drives 9 a common passive part, namely a maglev, which is firmly connected to the rail 5 is present or the rail 5 is designed as a magnetic track. The brackets 4 are each with one active part of a linear drive 9 , namely a coil, connected. Of course, the integrated guide system instead of just a rail 5 also have a pair of rails.

To the position of each bracket 4 to capture is per bracket 4 a linear measuring system exists, with all these linear measuring systems having a common measuring standard along the rail 5 is intended to be in communication.

The linear drives 9 of the integrated guidance system must be designed for only small ranges of motion, but for a very sensitive movement, since they only change the distance between the tracks 7 which are due to the process or due to leadership mistakes of the transport system 2 come about.

The integrated guidance system is via an additionally existing main linear drive 11 along a main rail 10 movable. The main linear drive 11 must be designed for a large range of motion, with no high demands placed on the sensitivity of the movement, at least not, although the reference structuring tool 3.1 at the rail 5 movably mounted.

The structuring tools 3 can be mechanical scoring tools, in particular scoring needles or laser beams, each emerging from a fiber laser or a laser head, in one of the holders 4 is mounted.

Every single mechanical structuring tool 3 is advantageously connected via an on / off valve with a pressure chamber, which makes it possible, the structuring tools involved in the structuring process 3 to vary. The pressure force of the individual structuring tools 3 is advantageously adjustable via a common proportional pressure regulator valve.

Basically, the necessary space, as per holder 4 is needed for the minimum possible distance of structuring tools 3 and thus determining the minimum possible track pitch. However, this limitation is not given by the integrated guidance system. So can between two brackets 4 also the distance between two non-adjacent tracks 7 , z. For example, the distance between every third track 7 , and after the misalignment of the rail 5 at the main rail 10 the tracks to be created in between 7 be structured.

LIST OF REFERENCE NUMBERS

1

Thin film solar cell module

2

transport means

3

structuring tool

3.1

Reference structuring tool

4

bracket

5

rail

6

Track detection unit

7

track

8th

Tracking control unit

9

linear actuator

10

Main rail

11

Main linear drive

12

process unit

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102006051555 B3 [0001, 0013]
• DE 19840936 B4 [0009, 0020, 0021, 0035]
• DE 102006051555 B4 [0012, 0014, 0017, 0020]

Claims (3)

Device for high-precision structuring of thin-film solar cell modules with a transport device ( 2 ) for receiving and transporting a thin-film solar cell module ( 1 ) in a transport direction perpendicular to the width of a received thin-film solar cell module ( 1 ), a process unit ( 12 ), which contain a variety of structuring tools ( 3 ) and on a rail ( 5 ) perpendicular to the transport direction independently controllable, movable brackets ( 4 ), and a track detection unit ( 6 ) for capturing and storing the track patterns and the position of already introduced tracks ( 7 ) and a tracking control unit ( 8th ), with the depending on the stored information existing linear drives ( 9 ), each with a holder ( 4 ), characterized in that each holder ( 4 ) exactly one structuring tool ( 3 ), the rail ( 5 ) on a main rail parallel thereto ( 10 ) perpendicular to the transport device ( 2 ) is movable and an additional with the rail ( 5 ) associated main linear drive ( 11 ) is present to the rail ( 5 ) across the width of a received thin film solar cell module ( 1 ) along the main rail ( 10 ). Device according to claim 1, characterized in that the linear drives ( 9 ) have a common passive part which acts as a magnetic track along the rail ( 5 ) is trained. Device according to claim 1, characterized in that one of the structuring tools ( 3 ) a reference structuring tool ( 3.1 ), which is fixed to the bracket ( 5 ) connected is.

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