Automated solar cell electrical connection apparatus

Abstract

The present invention generally relates to an automated solar cell electrical connection device that is positioned within an automated solar cell fabrication system. The automated solar cell electrical connection device includes a module and process for automatically attaching a junction box to a composite solar cell structure during the fabrication of a completed solar cell device. The automated solar cell electrical connection module may include a composite solar cell structure conveyor for positioning the composite solar cell structure, an adhesive dispense module for applying adhesive to the junction box, a flux dispenser for applying flux to electrical connection tabs in the junction box, a vision system for locating features on the composite solar cell structure, a robot for positioning the junction box onto the composite solar cell structure, a heating element to make electrical connections between the junction box and the solar cell device, a potting material dispensing assembly for dispensing potting material into the junction box, and a system controller for controlling the functions of the module.

1 . A solar cell electrical connection module, comprising:
 a head assembly supported by a gantry, wherein the gantry is located above a solar cell device conveyor, wherein the head assembly comprises:
 a vision system; 
 a robotic gripper; and 
 a heating assembly; 
   an actuator attached to the head assembly configured to move the head assembly in a first direction; and   a system controller configured to receive signals from the vision system and send signals to the head assembly.   
     
     
         2 . The module of  claim 1 , wherein the solar cell device conveyor is configured to move a solar cell device in a second direction, wherein the second direction is substantially perpendicular to the first direction. 
     
     
         3 . The module of  claim 1 , wherein the vision system comprises a camera configured to scan a solar cell device positioned on the solar cell device conveyor and a vision controller configured to locate electrical leads disposed on the solar cell device via signals sent from the camera. 
     
     
         4 . The module of  claim 1 , wherein the robotic gripper is configured to manipulate the position and orientation of the junction box and place the junction box on a solar cell device positioned on the solar cell device conveyor. 
     
     
         5 . The module of  claim 1 , wherein the heating assembly is configured to apply heat to the electrical leads disposed on a solar cell device positioned on the solar cell device conveyor. 
     
     
         6 . The module of  claim 1 , wherein the head assembly further comprises a potting material dispensing nozzle configured to apply a polymeric material to a region surrounding electrical leads disposed on a solar cell device dispose on the solar cell device conveyer. 
     
     
         7 . The module of  claim 1 , wherein the head assembly further comprises a lid retrieving robot configured to retrieve a junction box lid and place the lid on the junction box. 
     
     
         8 . The module of  claim 1 , further comprising a flux dispense nozzle positioned to apply flux to electrical connections in the junction box. 
     
     
         9 . A method of attaching a junction box to a solar cell device, comprising:
 applying an adhesive to a sealant surface of the junction box;   picking up the junction box via a robotic gripper;   moving a solar cell device in a first direction via a solar cell device conveyor;   scanning the solar cell device with a vision system to locate exposed electrical leads disposed on the solar cell device;   moving the junction box in a second direction via a head assembly and an actuator while rotationally reorienting the junction box;   positioning the junction box to align electrical connection points within the junction box with the exposed electrical leads on the solar cell device via information provided by the vision system;   placing the junction box onto the solar cell device;   positioning a heating element in contact with the electrical connection points using information provided by the vision system; and   heating the electrical connection points and the electrical leads to create an electrical connection therebetween.   
     
     
         10 . The method of  claim 9 , further comprising positioning a potting material dispensing nozzle in communication with an open region of the junction box using information provided by the vision system and dispensing the potting material to fill the junction box. 
     
     
         11 . The method of  claim 10 , further comprising placing a lid over the open region of the junction box using information provided by the vision system. 
     
     
         12 . The method of  claim 9 , wherein the electrical connection points are heated simultaneously. 
     
     
         13 . The method of  claim 9 , further comprising applying flux to the electrical connection points via a flux dispensing assembly. 
     
     
         14 . A solar cell electrical connection module, comprising:
 an adhesive dispense assembly configured to apply an adhesive to a sealant surface of a junction box;   a vision system configured to scan a solar cell device and locate positional features on the solar cell device;   a robotic gripper having gripping elements configured to pick up, manipulate, and place the junction box assembly onto the solar cell device;   a heating element configured to create an electrical connection between the junction box and the solar cell device;   an actuator attached to the vision system, the robotic gripper, and the heating element; and   a system controller configured to receive signals from the vision system and send signals to the robotic gripper and the heating element.   
     
     
         15 . The module of  claim 14 , wherein the actuator is configured to move the vision system, the robotic gripper, and the heating element in a first direction. 
     
     
         16 . The module of  claim 15 , further comprising a conveyor disposed beneath the robotic gripper and configured to move the solar cell device in a second direction substantially perpendicular to the first direction. 
     
     
         17 . The module of  claim 14 , further comprising a lid retrieving robot attached to the actuator and configured to retrieve a junction box lid and place the lid on the junction box. 
     
     
         18 . The module of  claim 14 , further comprising a potting material dispensing nozzle attached to the actuator and configured to apply a polymeric material to a region surrounding electrical leads disposed on the solar cell device.