Manufacturing of photovoltaic subassemblies
First Claim
1. A method for manufacturing a photovoltaic subassembly, the method comprising:
- loading a continuous roll of flexible and non-electrically conductive film into a work station such that a first terminal edge of the film, which defines a width thereof, is pulled away from the roll and extends between a first elevation and a second elevation at a first position, the film having an adhesive backing;
moving a first edge of a photovoltaic coating into proximity with the first position, such that the first terminal edge is approximately aligned with the first edge of the coating, for contact therewith, the photovoltaic coating being adhered to a central region of a major surface of a first substrate, the first substrate extending from the first elevation to the second elevation, and the first edge of the coating extending between the first and second elevations;
moving, in a generally horizontal direction, the first edge of the photovoltaic coating, from the first position to a second position, in order to draw a first portion of the film into adhesive contact with the coating, the first portion extending from the first terminal edge of the film toward the roll;
cutting an opening through a second portion of the film, when the first portion is in adhesive contact with the coating, the second portion extending from the second portion of the film toward the roll;
moving, in the generally horizontal direction, the first edge of the photovoltaic coating, from the second position to a third position, in order to draw the second portion of the film into adhesive contact with the coating, such that the opening in the second portion is approximately aligned with lead wires of the photovoltaic coating;
cutting along the width of the film, to separate a third portion of the film from a remainder of the film on the roll, the third portion extending from the second portion of the film to a second terminal edge of the film; and
moving, in the generally horizontal direction, a second edge of the photovoltaic coating, which is opposite the first edge, into proximity with the first position, in order to draw the third portion of the film into adhesive contact with the coating, such that the second terminal edge of the film is approximately aligned with the second edge of the coating.
1 Assignment
0 Petitions
Accused Products
Abstract
Some methods, and corresponding apparatus, for manufacturing photovoltaic subassemblies cause a plurality of desiccant beads to be adhered to an adhesive surface of sheet-like material; the sheet-like material is then, preferably, adhered to an exposed surface of a flexible and electrically non-conductive film, that covers a photovoltaic coating of a first substrate of the subassembly, such that the desiccant beads are held between the sheet-like material and the exposed surface. Some other methods, either alternatively or in addition to the above, include steps for applying the film, that covers the photovoltaic coating, wherein an opening, through the film, is cut, and then aligned, with lead wires of the photovoltaic coating, in the midst of applying the film.
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Citations
43 Claims
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1. A method for manufacturing a photovoltaic subassembly, the method comprising:
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loading a continuous roll of flexible and non-electrically conductive film into a work station such that a first terminal edge of the film, which defines a width thereof, is pulled away from the roll and extends between a first elevation and a second elevation at a first position, the film having an adhesive backing; moving a first edge of a photovoltaic coating into proximity with the first position, such that the first terminal edge is approximately aligned with the first edge of the coating, for contact therewith, the photovoltaic coating being adhered to a central region of a major surface of a first substrate, the first substrate extending from the first elevation to the second elevation, and the first edge of the coating extending between the first and second elevations; moving, in a generally horizontal direction, the first edge of the photovoltaic coating, from the first position to a second position, in order to draw a first portion of the film into adhesive contact with the coating, the first portion extending from the first terminal edge of the film toward the roll; cutting an opening through a second portion of the film, when the first portion is in adhesive contact with the coating, the second portion extending from the second portion of the film toward the roll; moving, in the generally horizontal direction, the first edge of the photovoltaic coating, from the second position to a third position, in order to draw the second portion of the film into adhesive contact with the coating, such that the opening in the second portion is approximately aligned with lead wires of the photovoltaic coating; cutting along the width of the film, to separate a third portion of the film from a remainder of the film on the roll, the third portion extending from the second portion of the film to a second terminal edge of the film; and moving, in the generally horizontal direction, a second edge of the photovoltaic coating, which is opposite the first edge, into proximity with the first position, in order to draw the third portion of the film into adhesive contact with the coating, such that the second terminal edge of the film is approximately aligned with the second edge of the coating. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 36, 37, 38, 39, 40, 41, 42)
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10. A method for manufacturing a photovoltaic subassembly, the method comprising:
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adhering a flexible and non-electrically conductive film to a photovoltaic coating so as to cover a significant surface area of the coating, the coating being adhered to a central region of a major surface of a first substrate, and a perimeter of the central region being surrounded by a peripheral region of the major surface; adhering a plurality of desiccant beads to an adhesive surface of a section of sheet material; and adhering the adhesive surface of the section of sheet material, which has the desiccant beads adhered thereto, to an exposed surface of the adhered film, such that the adhesive surface faces the exposed surface of the film and the plurality of desiccant beads are held between the section of sheet material and the exposed surface of the film the method further comprising forming an opening in the film in the midst of adhering the film to the photovoltaic coating, and wherein the opening is aligned with lead wires of the photovoltaic coating, when the film is adhered. - View Dependent Claims (11, 12, 13, 14, 23)
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15. A method for manufacturing a photovoltaic subassembly, the method comprising:
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adhering a flexible and non-electrically conductive film to a photovoltaic coating so as to cover a significant surface area of the coating, the coating being adhered to a central region of a major surface of a first substrate, and a perimeter of the central region being surrounded by a peripheral region of the major surface; adhering a plurality of desiccant beads to an adhesive surface of a section of sheet material; and adhering the adhesive surface of the section of sheet material, which has the desiccant beads adhered thereto, to an exposed surface of the adhered film, such that the adhesive surface faces the exposed surface of the film and the plurality of desiccant beads are held between the section of sheet material and the exposed surface of the film the method further comprising applying a spacer member only to the peripheral region of the major surface of the first substrate, after adhering the adhesive surface of the sheet material, the spacer member for joining a second substrate to the first substrate, in spaced relation thereto. - View Dependent Claims (16, 17, 18)
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19. A method for incorporating desiccant into each of a plurality of assemblies, each assembly including a first substrate having a major surface, the major surface including a central region over which a photovoltaic coating extends, and a peripheral region surrounding a perimeter of the photovoltaic coating, the method comprising:
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allowing a plurality of desiccant beads to fall over a plurality of deflectors, the plurality of deflectors being arranged such that the falling beads ricochet laterally therefrom; positioning an adhesive surface of sections of sheet material face-to-face with the deflectors, while the desiccant beads are falling, such that the ricocheting desiccant beads bombard the adhesive surfaces and adhere thereto; adhering each of the sections of the sheet material, to which the desiccant beads are adhered, to a corresponding first substrate, such that the adhered desiccant beads of each section are positioned between the corresponding section of sheet material and the photovoltaic coating of the corresponding first substrate; applying a spacer member only to the peripheral region of the major surface of each of the first substrates, after adhering the corresponding section of sheet material; bringing each of a plurality of second substrates face-to-face with each corresponding first substrate, such that a peripheral region of each second substrate is aligned with the peripheral region of the corresponding first substrate, the peripheral region of each second substrate surrounding a central region thereof; and joining each second substrate to the corresponding first substrate, by pressing the first and second substrates together, with the corresponding spacer member sandwiched therebetween, such that an airspace is maintained between each pair of first and second substrates. - View Dependent Claims (20, 21, 22)
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24. An assembly line for manufacturing photovoltaic assemblies, the assembly line comprising:
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a first workstation including a film application work head for adhering a flexible and electrically non-conductive film to each of a plurality of photovoltaic coatings, as each coating is conveyed past the film application work head, so as to cover a surface area of each coating, each coating being previously adhered to a central region of a major surface of a corresponding first substrate of a plurality of first substrates; a second workstation including a desiccant sheet application work head for adhering a sheet material, to which a plurality of desiccant beads have been previously adhered, to an exposed surface of the adhered film of each first substrate after each first substrate is conveyed to the second workstation, such that each plurality of desiccant beads is held against the exposed surface of each adhered film by the sheet material; a third workstation for applying a first member of a seal system along an inner portion of a peripheral region of the major surface of each first substrate, each peripheral region surrounding a perimeter of the central region of the corresponding first substrate; a fourth workstation for pressing a second substrate together with each first substrate, such that the applied first member of the seal system of each first substrate is sandwiched between the peripheral region of each first substrate and a peripheral region of a corresponding second substrate, and an air space is maintained between each pair of first and second substrates; and a fifth workstation for applying a second member of the seal system into an outer perimeter channel of each pressed together pair of first and second substrates, each outer perimeter channel being external to the corresponding first member of the seal system of each pressed together pair and extending along outer portions of the peripheral regions thereof. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31)
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32. An assembly line for manufacturing photovoltaic assemblies, the assembly line comprising:
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a first workstation including a film application work head, a cutting tool, a spindle, and a continuous roll of a flexible and electrically non-conductive film mounted on the spindle, the film including an adhesive backing and the spindle allowing the film to be drawn from the mounted roll, the film application work head including a pinch roller for driving each of a plurality of first substrates through the first workstation and to, thereby, both draw the film from the mounted roll and to adhere a section of the film to each of a plurality of photovoltaic coatings, so as to cover a surface area of each coating, each coating being previously adhered to a central region of a major surface of a corresponding first substrate of the plurality of first substrates, and the cutting tool being located between the spindle and the film application work head, the cutting tool for cutting an opening through each section of the film before an entirety of each section is adhered to the corresponding photovoltaic coating; a second workstation for applying a first member of a seal system along an inner portion of a peripheral region of the major surface of each first substrate, each peripheral region surrounding a perimeter of the central region of the corresponding first substrate; a third workstation for pressing a second substrate together with each first substrate, such that the applied first member of the seal system of each first substrate is sandwiched between the peripheral region of each first substrate and a peripheral region of a corresponding second substrate, and an air space is maintained between each pair of first and second substrates; and a fourth workstation for applying a second member of the seal system into an outer perimeter channel of each pressed together pair of first and second substrates, each outer perimeter channel being external to the corresponding first member of the seal system of each pressed together pair and extending along outer portions of the peripheral regions thereof. - View Dependent Claims (33, 34, 35)
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43. A method for manufacturing a photovoltaic subassembly, the method comprising:
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loading a continuous roll of flexible and non-electrically conductive film into a work station such that a first terminal edge of the film, which defines a width thereof, is pulled away from the roll and extends between a first elevation and a second elevation at a first position, the film being formed of a polyethylene, polypropylene, or polyester material and having a thickness of between approximately 0.001 inch and approximately 0.015 inch and having an adhesive backing; moving a first edge of a photovoltaic coating into proximity with the first position, such that the first terminal edge is approximately aligned with the first edge of the coating, for contact therewith, the photovoltaic coating being adhered to a central region of a major surface of a first substrate, the first substrate being light transmitting glass, the first substrate extending from the first elevation to the second elevation, and the first edge of the coating extending between the first and second elevations; moving, in a generally horizontal direction, the first edge of the photovoltaic coating, from the first position to a second position, in order to draw a first portion of the film into adhesive contact with the coating, the first portion extending from the first terminal edge of the film toward the roll; cutting an opening through a second portion of the film, when the first portion is in adhesive contact with the coating, the second portion extending from the second portion of the film toward the roll; moving, in the generally horizontal direction, the first edge of the photovoltaic coating, from the second position to a third position, in order to draw the second portion of the film into adhesive contact with the coating, such that the opening in the second portion is approximately aligned with a lead wire location of the photovoltaic coating; cutting along the width of the film, to separate a third portion of the film from a remainder of the film on the roll, the third portion extending from the second portion of the film to a second terminal edge of the film; and moving, in the generally horizontal direction, a second edge of the photovoltaic coating, which is opposite the first edge, into proximity with the first position, in order to draw the third portion of the film into adhesive contact with the coating, such that the second terminal edge of the film is approximately aligned with the second edge of the coating.
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Specification