Solarcity Corporation

Brooks Automation Gmbh

Pablo Gonzalez

Bobby Yang

Peter P Nguyen

Gary Roy Watts

Jiunn Benjamin Heng

Christoph Georg Erben

Ben Chung

Ming-Du Kang

Rey Ilagan

Lilja Magnusdottir

A cleaving system and method are described. The system can include a holding apparatus to retain a photovoltaic structure at a center section of a cleaving platform. The system can further include a contact apparatus to make contact with the photovoltaic structure and separate it into a plurality of strips. During operation, the system can activate an actuator to move the contact apparatus against the photovoltaic structure, thereby separating the photovoltaic structure into strips.

Photovoltaic structure cleaving system

An access arbitration module includes a plurality of active component communication ports for communicating with a plurality of active components, and includes a passive component communication port for communicating with a passive component. The access arbitration module also includes switching logic defined to control transmission of access communication protocol signals between each of the plurality of active component communication ports and the passive component communication port, such that an authorized one of the plurality of active component communication ports is connected in communication with the passive component communication port at a given time, and such that non-authorized ones of the plurality of active component communication ports are prevented from communication with the passive component communication port at the given time.

Access arbitration system for semiconductor fabrication equipment and methods for using and operating the same

A targeted-annealing system can automatically cure a conductive paste that may bind cascaded strips of a string together without damaging the strips. The targeted-annealing system can process strings of cascaded strips on a supporting surface, and can anneal conductive paste between overlapping strips by blowing heated air on the overlapping sections of the strips. An air nozzle shaped to target the overlapping sections may provide the heated air. The supporting surface may include a porous material that allows a vacuum to pull on the cascaded strips from below the surface during the annealing process.

System for targeted annealing of PV cells

Devices and methods for transferring solar cells while maintaining a controlled environment are provided. Such devices include a solar cell carrying cassette adapted to support a stack of solar cells within a solar cell carrying pod that maintains a sealed micro-environment of inert gas and allows for automated transfer of solar cells between the pod and a fabrication line. The solar cell carrying cassette includes a pair of end plates and a plurality of rods extending therebetween that are configured to support a stack of solar cells. An identifier, such as an RFID chip, is included in each of the pair of end plates so as to allow for ready identification of the cassette from a single location relative the pod, while the cassette is coupled within the pod, regardless of the orientation of the cassette within the pod.

Ambidextrous cassette and methods of using same

A two piece electroplating frame or electroplating frame is disclosed that is suitable for holding multiple solar cells during an electroplating operation. The electroplating frame can be formed from or at least covered with non-conductive material to reduce the collection of plating material on the electroplating frame. The two pieces of the electroplating frame can be coupled together around the solar cells by magnets distributed throughout the electroplating frame. The electroplating frame can include alignment features for self-aligning the assembly of the two pieces without requiring precise pre-alignment.

Systems, methods and apparatus for electroplating photovoltaic cells

Devices and methods for transferring solar cells while maintaining a controlled environment are provided. Such devices can include a solar cell carrying pod adapted to support and maintain a stack of solar cells within a sealed micro-environment of inert gas. The solar cell carrying pod can further allow for ready removal of a solar cell carrier to facilitate automated transport of solar cells. The solar cell carrying pod can include a cover adapted to receive a solar cell carrier cassette securely mounted on a base that is sealably coupled with the cover to maintain solar cells within the carrier cassette in a sealed micro-environment for an extended period of time. The base can include a collet-operated gear train to facilitate unlocking and removal of the base from the cover in an automated process to facilitate large-scale solar cell fabrication.

Micro-environment container for photovoltaic cells

A targeted-annealing system can automatically cure a conductive paste that may bind cascaded strips of a string. The targeted-annealing system can include a first heat-treating bar that may be heated to a first curing temperature, and can include a second heat-treating bar that may be heated to a second curing temperature. During operation, a controller of the targeted-annealing system can activate one or more actuators to conform the first heat-treating bar to a top surface of two cascaded strips, and conform the second heat-treating bar to a bottom surface of two cascaded strips. The first and second heat-treating bars may be aligned along an overlap portion between the two cascaded strips, and can heat the overlap portion to 160 degrees Celsius.

Systems and methods for targeted annealing of photovoltaic structures

A string-forming system is described. The string-forming system may include at least a first cell-lifting mechanism and a second cell-lifting mechanism that can automatically arrange a set of strips of a photovoltaic structure into a cascaded formation. During operation, a controller can cause the first cell-lifting mechanism to lift a first strip from a first platform, and can cause the second cell-lifting mechanism to lift, from the first platform, a second strip that may follow the first strip on the first platform. The controller may then activate a first shifting actuator of the first cell-lifting mechanism or a second shifting actuator of the second cell-lifting mechanism to place a leading edge of the second strip above a trailing edge of the first strip.

Systems and methods for cascading photovoltaic structures

Systems and methods for transferring solar cells while maintaining a controlled micro-environment are provided. In particular, such systems provide automated loading and unloading of solar cells by use of a conveyor and elevator within a tank receptacle sealingly connected with a solar cell carrying pods and a flow tube of solar cell components in a solar cell fabrication process. The tank receptacle can include one or more ports for sealingly and operably coupling with a cover of a solar cell carrying pod, each port having an elevator for withdrawing a removable base of the pod along with a solar cell carrying cassette into the tank and a conveyor to facilitate loading and/or unloading of solar cells with the cassette by coordinated movement of the elevator and conveyor. Such systems can further include a robotic arm having a gripper and nozzle to maintain a micro-environment within the pod during transport.

Load lock solar cell transfer system

One embodiment of the present invention provides an apparatus for attaching conductive tabs to photovoltaic structures. The apparatus includes a cassette configured to store a plurality of conductive tabs and a pick-and-place apparatus configured to obtain a conductive tab from the cassette and place the conductive tab at an edge of a photovoltaic structure. The pick-and-place apparatus further includes a tab holder configured to pick up and release the conductive tab and a substantially horizontal track coupled to the tab holder. The tab holder is further configured to move back and forth along the track.

System and apparatus for precision automation of tab attachment for fabrications of solar panels

A method for constructing a photovoltaic (PV) substrate. A moving frame can be lowered towards a stack of back sheets and a back sheet of the stack of back sheets may be secured to the moving frame. The back sheet can be transferred from the moving frame to a vacuum table. An adhesive can be dispensed to the back sheet using an adhesive dispenser. At least one string may be placed onto the adhesive applied to the back sheet. The vacuum table can be rotated, and the back sheet can be released from the vacuum table onto a glass sheet.

Systems and method for precision automated placement of backsheet on PV modules

One embodiment of the invention provides an apparatus for dispensing conductive paste on photovoltaic structures during manufacturing of a solar panel. The apparatus includes a cartridge for holding the conductive paste, a jet-dispensing module coupled to the cartridge, and a robotic arm coupled to the jet-dispensing module. The jet-dispensing module is configured to dispense a predetermined amount of the conductive paste on busbars of a respective photovoltaic structure in a non-contact manner, and the robotic arm is configured to adjust a position of the jet-dispensing module, thereby facilitating alignments between the jet-dispensing module and the busbars of the photovoltaic structure.

Systems for precision application of conductive adhesive paste on photovoltaic structures

A photovoltaic module can be constructed from one or more strings, with each of the strings being constructed from a plurality of cascaded solar cells. A connector can electrically connect the strings to one another. The connector can include strain relief connectors that extend between the connector and the strings to help reduce effects caused by thermal expansion.

Strain relief apparatus for solar modules

A system for processing solar cells is disclosed which includes a separation module for separating a processing frame from solar cells that are fed along a conveyance line. The processing frame can be separated without requiring manual lifting of the processing frame by feeding the processing frame and solar cells into a magnetic roller system. The magnetic roller system can gradually lift the processing frame away from the solar cells and divert the processing frame to a separate roller system. The solar cells can remain on the main conveyance line for further processing.

Systems for levitating a metallic tray

Systems and methods for manufacturing solar panels are disclosed. Solar cells are placed on a conveyor that transports the cells from a start point to an end point. A laser scribing module scribes the cells at a predetermined depth. A paste dispensing module deposits a predetermined amount of conductive paste on the surface of the solar cells. A cleaving apparatus divides the cells into smaller strips. A shingling module creates a string of cells by overlapping the strips. A targeted annealing module cures the paste, and a layup module places the strings on a backsheet. A glass cover is then added to one side of the strings.

Growing community of inventors

Fremont, CA, United States of America

Pablo Gonzalez