Edge processing of photovoltaic substrates
View Patent ↗A method for processing a coated glass substrate may include a high-temperature activation process.
1. A method of processing a plurality of coated glass photovoltaic substrates, the method comprising:
removing a coating from one or more edges of each of a plurality of photovoltaic glass substrates having a coated surface;
after removing the coating, shaping an edge of each of the plurality of glass substrates;
after shaping the edge of each of the plurality of glass substrates, washing the plurality of glass substrates;
after washing the plurality of glass substrates, grouping the plurality of glass substrates into batches for annealing, each batch comprising two or more of the plurality of glass substrates; and,
batch annealing the entirety of each of the plurality of grouped glass substrates.
2. The method of claim 1 , wherein the shaping comprises grinding one or more edges of each of the plurality of glass substrates.
3. The method of claim 1 , wherein the annealing further comprises loading each batch of glass substrates into a thermal processing chamber, and the loading comprises transporting each of the plurality of glass substrates using the one or more edges from which the coated surface is removed and without physically contacting the coated surface thereof.
4. The method of claim 3 , wherein the loading further comprises placing the plurality of glass substrates on one or more ceramic rollers, wherein the thermal processing chamber comprises the one or more ceramic rollers.
5. The method of claim 4 , further comprising oscillating the one or more ceramic rollers back and forth during the annealing.
6. The method of claim 1 , further comprising stacking the plurality of annealed glass substrates by positioning each of the plurality of glass substrates vertically adjacent to one another such that a coated surface of one of the plurality of glass substrates does not contact a bottom surface of a vertically adjacent one of the plurality of glass substrates.
7. The method of claim 6 , wherein the stacking further comprises applying glass separation media between each of the plurality of glass substrates.
8. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates above about 300 degrees C.
9. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates below about 800 degrees C.
10. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates for more than about 5 minutes.
11. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates for less than about 30 minutes.
12. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates under an ambient atmosphere condition.
13. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates in an atmosphere comprising a forming gas.
14. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates in an atmosphere comprising a hydrogen gas.
15. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates in an atmosphere comprising a nitrogen gas.
16. The method of claim 1 , wherein the annealing comprises heating each batch of glass substrates in an atmosphere comprising an oxygen gas.
17. The method of claim 1 , wherein the washing comprises:
depositing each of the plurality of glass substrates in a receptacle; and
rinsing each of the plurality of glass substrates in a solution.
18. The method of claim 1 , wherein the annealing comprises heating the plurality of glass substrates in a roller hearth.
19. The method of claim 1 , wherein the annealing comprises heating the plurality of glass substrates in a thermal processing chamber.
20. The method of claim 1 , wherein the annealing comprises heating the plurality of glass substrates in a muffle tube oven.
21. The method of claim 1 , wherein the annealing comprises heating the plurality of glass substrates in a belt furnace.
22. The method of claim 1 , wherein the grouping comprises aggregating the plurality of glass substrates into batches of two or more.
23. The method of claim 1 , wherein the grouping comprises aggregating the plurality of glass substrates into batches of three or less.
24. The method of claim 1 , wherein the grouping comprises aggregating the plurality of glass substrates into batches comprising a side-by-side configuration.
25. The method of claim 1 , wherein the grouping comprises aggregating the plurality of glass substrates into batches comprising a stacked configuration.
26. The method of claim 1 , further comprising inspecting the plurality of glass substrates after annealing each batch.
27. The method of claim 1 , wherein the plurality of coated glass substrates are each coated with at least one photovoltaic module material.
28. The method as in claim 27 , wherein the photovoltaic module material comprises a transparent conductive oxide material layer.
29. The method as in claim 28 , wherein the photovoltaic module material further comprises one or more semiconductor material layers.
30. The method as in claim 29 , wherein the photovoltaic module material further comprises one or more back contact layers.