Granted Patent B1

US 8,513,095 · App. 12/200,915 · Granted Aug 20, 2013

Abstract

Claims (57)

1. A method for manufacturing solar strips, the method comprising:

providing a photovoltaic material having a thickness, the photovoltaic material including a backside surface and a front side, a plurality of photovoltaic strip regions having at least five strip regions, a plurality of scribe regions separating the plurality of photovoltaic strip regions, wherein a scribe region from the plurality of scribe regions includes a depth, the depth being less than the thickness of the photovoltaic material, the scribe region dividing the photovoltaic material into a first portion and a second portion of the photovoltaic material;

providing a support material;

positioning the photovoltaic material such that the first portion is supported by the support material and the second portion is unsupported by the support material, the second portion including at least one photovoltaic strip region;

applying a pre-determined force comprising a sheer force and a break force along the second portion to cause the second portion to be separated from the first portion;

moving a remaining portion of the photovoltaic material by a distance of an integer multiple of a width of a photovoltaic strip region such that a third portion of the photovoltaic material is supported by the support material and a fourth portion of the photovoltaic material is unsupported by the support material, wherein the fourth portion includes at least one photovoltaic strip region;

applying a pre-determined force along the fourth portion to cause the fourth portion to be separated from the third portion; and

repeating moving and applying the pre-determined force to any remaining portions of the photovoltaic material until the remaining portions have been exhausted,

wherein the plurality of photovoltaic strip regions are parallel to each other.

2. The method of claim 1 wherein the pre-determined force is substantially free of a component that pushes the second portion into the first portion.

3. The method of claim 1 wherein the pre-determined force includes a component that pulls the second portion away from the first portion.

4. The method of claim 1 wherein the pre-determined force includes a component that causes the second portion to shear away from the first portion along the scribe region.

5. The method of claim 1 wherein the pre-determined force includes a distributed force.

6. The method of claim 1 wherein the pre-determined force includes a component that causes the second portion to shear away from the first portion along a crystal plane in the photovoltaic material.

7. The method of claim 1 further comprising producing a detached photovoltaic member and moving the detached photovoltaic member along the support member.

8. The method of claim 7 further comprising removing the detached photovoltaic member with an external device.

9. The method of claim 8 wherein the external device includes a pick.

10. The method of claim 7 wherein the detached photovoltaic member moves along the support member in an upright manner.

11. The method of claim 7 wherein the detached photovoltaic member moves along the support member without flipping over.

12. The method of claim 1 wherein the depth of each of the plurality of scribe regions ranges from about 30 to about 90 percent of the thickness of the photovoltaic material.

13. The method of claim 1 wherein the depth of each of the plurality of scribe regions is the same.

14. The method of claim 1 wherein the width of each of the plurality of scribe regions ranges is the same.

15. The method of claim 1 wherein the plurality of photovoltaic strip regions has a characteristic width, the method further comprising moving the photovoltaic material by an integer multiple of the characteristic width.

16. The method of claim 14 wherein the characteristic width is the width of a photovoltaic strip region, wherein the width of each of the plurality of scribe regions ranges is similar.

17. The method of claim 1 wherein positioning the photovoltaic material includes:

placing the photovoltaic material on a top surface of the support member such that at least a portion of the backside surface of the photovoltaic material faces the top surface of the support member; and

applying a force to the first portion such that at least a portion of backside surface of the photovoltaic material is substantially flush with the top surface.

18. The method of claim 17 wherein the applying of the force to the first portion includes providing a vacuum on a portion of the backside surface.

19. The method of claim 17 wherein the applying of the force to the first portion does not require the use of a tape.

20. The method of claim 17 wherein the applying of the force to the first portion includes clamping the photovoltaic material to the support material.

21. The method of claim 17 wherein the applying of the force to the first portion includes applying a distributed force to the front side surface.

22. The method of claim 1 further comprising providing a hammer-like device to apply the pre-determined force.

23. The method of claim 1 wherein the pre-determined force does not cause kerf loss in the photovoltaic material.

24. The method of claim 1 wherein the photovoltaic material includes at least one metal layer and at least one passivation layer.

25. The method of claim 1 wherein each of the plurality of photovoltaic strip regions includes at least one P-N junction.

26. The method of claim 25 wherein each of the at least one P-N junction divides each of the photovoltaic strip regions into at least one set of P-N regions along a length of each of the plurality of photovoltaic strip regions.

27. The method of claim 25 wherein each of the at least one P-N junction divides each of the plurality of photo voltaic strip regions into at least one set of P-N regions normal to a length of each of the plurality of photovoltaic strip regions.

28. The method of claim 25 wherein the at least one metal layer is located on the back side region of the photovoltaic material.

29. The method of claim 25 wherein the at least one P-N junction remains free of defect before and after the application of the pre-determined force.

30. The method of claim 25 wherein the at least one metal layer remains free of defect before and after the application of the pre-determined force.

31. The method of claim 25 wherein the at least one passivation layer remains free of defect before and after the application of the pre-determined force.

32. The method of claim 25 further comprising providing an oxygen flow over the photovoltaic material.

33. The method of claim 25 further comprising providing a nitrogen flow over the photovoltaic material.

34. The method of claim 25 further comprising providing a water flow over the photovoltaic material.

35. A method for manufacturing solar strips, the method comprising:

providing a photovoltaic material having a thickness, the photovoltaic material including a backside surface and a front side, a plurality of photovoltaic strip regions having at least five strip regions, a plurality of scribe regions separating the plurality of photovoltaic strip regions, wherein a scribe region from the plurality of scribe regions includes a depth, the depth being less than the thickness of the photovoltaic material, the scribe region dividing the photovoltaic material into a first portion and a second portion of the photovoltaic material;

providing a support material;

positioning the photovoltaic material such that the first portion is supported by the support material and the second portion is unsupported by the support material, the second portion including at least one photovoltaic strip region;

applying a pre-determined force along the second portion to cause the second portion to be separated from the first portion;

moving a remaining portion of the photovoltaic material by a distance of an integer multiple of a width of a photovoltaic strip region such that a third portion of the photovoltaic material is supported by the support material and a fourth portion of the photovoltaic material is unsupported by the support material, wherein the fourth portion includes at least one photovoltaic strip region;

applying a pre-determined force along the fourth portion to cause the fourth portion to be separated from the third portion; and

repeating moving and applying the pre-determined force to remaining portions of the photovoltaic material until remaining portions have been exhausted,

wherein the plurality of photovoltaic strip regions are parallel to each other.

36. The method of claim 1

wherein a support material comprises an oblique side surface, and

wherein the applying the pre-determined force along the second portion comprises applying the pre-determined force along the second portion to cause the second portion to be separated from the first portion and slide down the oblique side surface of the support material.

37. The method of claim 35 wherein the positioning the photovoltaic material comprises positioning the photovoltaic material such that the first portion is positioned above a top surface of the support material and is supported by the support material and the second portion positioned above the oblique side surface of the support material but is not supported by the oblique side surface of the side surface.

Assignments (13)