U.S. patent application number 14/597393 was filed with the patent office on 2015-05-07 for quick release head for tape applicator.
The applicant listed for this patent is FIRST SOLAR, INC.. Invention is credited to Brian Maus, Thomas Truman.
Application Number | 20150122424 14/597393 |
Document ID | / |
Family ID | 47020376 |
Filed Date | 2015-05-07 |
United States Patent
Application |
20150122424 |
Kind Code |
A1 |
Maus; Brian ; et
al. |
May 7, 2015 |
QUICK RELEASE HEAD FOR TAPE APPLICATOR
Abstract
A double sided tape applicator can include a quick release head
to facilitate, for example, cleaning and tape threading.
Inventors: |
Maus; Brian; (Britton,
MI) ; Truman; Thomas; (Toledo, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FIRST SOLAR, INC. |
Perrysburg |
OH |
US |
|
|
Family ID: |
47020376 |
Appl. No.: |
14/597393 |
Filed: |
January 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13451635 |
Apr 20, 2012 |
8951381 |
|
|
14597393 |
|
|
|
|
61478890 |
Apr 25, 2011 |
|
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Current U.S.
Class: |
156/577 |
Current CPC
Class: |
Y10T 156/1348 20150115;
Y10T 156/17 20150115; Y10T 156/1795 20150115; B65H 35/0013
20130101; B65H 37/002 20130101; Y10T 156/12 20150115; B65H
2402/5155 20130101 |
Class at
Publication: |
156/577 |
International
Class: |
B65H 37/00 20060101
B65H037/00 |
Claims
1. A quick release head for a tape applicator, the head comprising:
a first portion; a second portion substantially parallel to the
first portion; a plurality of rollers positioned between the first
and second portions; and a first quick release device allowing
attachment or removal of the head to or from a tape applicator.
2. The quick release head of claim 1, further comprising: a second
quick release device allowing attachment or removal of the first
portion to or from the second portion.
3. The quick release head of claim 1, wherein the plurality of
rollers comprises: a first roller mounted on a first axle; a second
roller mounted on a second axle; and a third roller mounted on a
third axle, wherein the first, second, and third axles extend from
the first portion to the second portion.
4. The quick release head of claim 1, wherein the first quick
release device is a quick release skewer.
5. The quick release head of claim 1, wherein the first quick
release device comprises a mating feature on the tape applicator
head configured to interlock with a mating feature on the tape
applicator.
6. The quick release head of claim 1, further comprising a cutter
mounted to the head, wherein the cutter is configured to sever tape
proximate to the plurality of rollers.
7. A tape applicator comprising: a body; a first spindle attached
to the body and configured to receive a supply roll; a second
spindle attached to the body and configured to receive a rewind
roll; and a quick release head attached to the body by a first
quick release device.
8. The tape applicator of claim 7, wherein the first quick release
device is a quick release skewer.
9. The tape applicator of claim 7, wherein the first quick release
device comprises a mating feature on the quick release head
configured to interlock with a mating feature on the body.
10. The tape applicator of claim 7, wherein the quick release head
comprises: a first portion; a second portion substantially parallel
to the first portion; and a plurality of rollers positioned between
the first and second portions.
11. The tape applicator of claim 10, further comprising a second
quick release device allowing attachment or removal of the first
portion to or from the second portion.
12. The tape applicator of claim 10, wherein the plurality of
rollers comprises: a first roller mounted on a first axle; a second
roller mounted on a second axle; and a third roller mounted on a
third axle, wherein the first, second, and third axles extend from
the first portion to the second portion.
13. The tape applicator of claim 7, further comprising a cutter
mounted to the quick release head, wherein the cutter is configured
to sever tape routed through the plurality of rollers.
14-20. (canceled)
21. A tape applicator system comprising: a tape applicator
comprising a body, the body comprising: a supply roll for supplying
an insulating tape; a first quick release head for applying the
insulating tape adjacent to a portion of a partially completed
photovoltaic module, the first quick release head comprising: at
least one first application roller; and a first actuatable quick
release device for releasing the first quick release head from the
body of the tape applicator; and a second quick release head
attachable to the body of the tape applicator when the first quick
release head is released from the body of the tape applicator, the
second quick release head comprising: at least one second
application roller; and a second actuatable quick release
device.
22. The tape applicator system of claim 21, wherein the first
actuatable quick release device is a quick release skewer.
23. The tape applicator system of claim 21, wherein the first
actuatable quick release device comprises a first mating feature on
a first portion of the first quick release head configured to
interlock with a second mating feature on a second portion of the
first quick release head.
24. The tape applicator system of claim 21, the first quick release
head further comprising: a first portion; and a second portion
substantially parallel to the first portion, wherein the at least
one first application roller is positioned between the first and
second portions.
25. The tape applicator system of claim 24, wherein the second
actuatable quick release device allows attachment or removal of the
first portion to or from the second portion.
Description
CLAIM OF PRIORITY
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application Ser. No.
61/478,890 filed on Apr. 25, 2011, which is hereby incorporated by
reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a tape applicator with a
quick release head and a method for manufacturing photovoltaic
modules.
BACKGROUND
[0003] A photovoltaic (PV) module converts light to electricity.
During manufacturing of the module, strips of conductive foil can
be used to make electrical connections within the module. For
example, strips of conductive foil can be used to connect one or
more sub-modules within the module. To prevent movement of the foil
strips, which can result in shorting, sections of double sided tape
may be applied between the foil strips. The double sided tape may
be applied using an automated tape applicator, and the applicator
may include a head through which the adhesive tape is routed.
During use, the head may experience a build-up of adhesive from the
passing tape. The build-up of adhesive can reduce accuracy and
reliability of the tape applicator.
DESCRIPTION OF DRAWINGS
[0004] FIG. 1 is a side view of a double sided tape applicator.
[0005] FIG. 2 is an exploded view of an example quick release
head.
[0006] FIG. 3 is a perspective view of an example quick release
head.
[0007] FIG. 4 is an exploded view of an example quick release
head.
[0008] FIG. 5 is a perspective view of an example quick release
head.
[0009] FIG. 6 is a side view of a double sided tape applicator.
[0010] FIG. 7 is an exploded view of a partially assembled
photovoltaic module.
[0011] FIG. 8 is an exploded view of a partially assembled
photovoltaic module.
[0012] FIG. 9 is a perspective view of a partially assembled
photovoltaic module.
[0013] FIG. 10 is a perspective view of an example quick release
head.
[0014] FIG. 11 is an exploded view of a partially assembled
photovoltaic module.
[0015] FIG. 12 is an exploded view of a partially assembled
photovoltaic module.
[0016] FIG. 13 is a side view of a partially assembled photovoltaic
module.
[0017] FIG. 14 is a side view of a partially assembled photovoltaic
module.
[0018] FIG. 15 is a side view of a partially assembled photovoltaic
module.
DETAILED DESCRIPTION
[0019] During the manufacture of a photovoltaic module, strips of
conductive foil may serve as positive and negative leads to a
module. Often the foil leads are stacked on top of each other and
an insulating tape is positioned between the foil leads. The
insulating tape prevents short-circuiting between the conductive
strips. While the tape may be positioned manually, it is far more
efficient to use an automated tape applicator. Unfortunately,
existing tape applicators suffer from frequent accumulation of
adhesive left behind by the passing tape. Cleaning and removing the
adhesive from the tape applicator requires stopping an assembly
line to service the tape applicator. Since the tape applicator must
be cleaned frequently, downtime associated with servicing the tape
applicator can be considerable. Therefore, to remedy the
shortcomings of existing tape applicators, an improved tape
applicator with a quick release head has been devised and is set
forth herein.
[0020] Referring by way of example to FIG. 1, a tape applicator 100
may be configured to apply tape 110 to a surface. For example, the
tape applicator 100 may be configured to apply tape 110 onto a
surface 155 of a photovoltaic module 145. The tape 110 may be any
suitable double-sided tape, such as 3M's Double Coated Dielectric
Tape 3514, and may include a primary layer 115 and a backing layer
120. The primary layer 115 may be formed from any suitable
insulating material such as polyester (PET). The primary layer may
include a first surface and a second surface opposite the first
surface, and each surface may be coated with adhesive. The adhesive
may be any suitable adhesive such as, for example, acrylic
adhesive. The backing layer 120 may be a removable layer that is
easily separated from the adhesive-coated primary layer. The
backing layer 120 may include, for example, poly-coated craft
paper, wax paper, or any other suitable material. Removal of the
backing layer 120 may expose adhesive on one surface of the primary
layer 115.
[0021] Before discussing various aspects of the tape applicator
100, it is useful to discuss a couple of ways in which the tape
applicator can be used to manufacture photovoltaic modules. In a
first example, as shown in FIG. 7, a partially completed
photovoltaic module 145 can include a first conductor 705 and a
second conductor 710. The conductors (705, 710) can include any
suitable electrical conductor, such as conductive tape or foil and
can have any suitable shape. The first and second conductors (705,
710) may serve as positive and negative leads for the module
145.
[0022] During manufacturing, the primary layer 115 of tape may be
applied between the first and second conductors (705, 710) and may
serve as an insulating barrier between the conductors. For example,
when manufacturing the module 145, the first conductor 705 may be
formed adjacent to a surface 155 of the module 145. Then, the
primary layer 115 of tape may be formed adjacent to the first
conductor 705, and the second conductor 710 may be formed adjacent
to the primary layer 115 of tape. The relative positions of the
primary layer 115 of tape and the conductors (705, 710) are shown
in FIG. 7, which shows an exploded view of a partially assembled
module 145. Once the conductors (705, 710) and the primary layer
115 of tape have been formed, a cover plate 805 having an opening
810 may be added to the module 145 as shown in FIG. 8. The first
and second sections of conductor (705, 710) may then be folded back
against the cover plate 805 to serve as positive and negative leads
for the module 145, as shown in FIG. 9. A junction box, also known
as a cord plate, may be placed over the positive and negative
leads, thereby facilitating electrical connectivity to other
modules or components.
[0023] In a second example, as shown in FIGS. 11-15, the primary
layer 115 of tape may be applied to the surface 155 of the
partially completed photovoltaic module 145. A single conductor
1105 may then be formed adjacent to the primary layer 115 of tape.
A loop 1110 may be formed in the conductor thereby allowing it to
protrude through the opening 810 in the cover plate 805, as shown
in the cross-sectional side view in FIG. 13. Once the cover plate
805 has been installed, the conductor 1105 may be severed to form
the first and second sections of conductor (705, 710), as shown in
FIG. 14. The first and second sections of conductor (705, 710) may
then be folded back against the cover plate 805 to serve as
positive and negative leads for the module 145, as shown in FIG.
15. A junction box, also known as a cord plate, may be placed over
the positive and negative leads, thereby facilitating electrical
connectivity to other modules or components.
[0024] The tape applicator 100 may include a quick-release head 140
attached to a body 170 of the applicator 100 as shown, by way of
example, in FIG. 1. The head 140 may include a plurality of rollers
(e.g. 141, 142, 143), and the rollers may be attached to the head
140 by a plurality of axles (e.g. 241, 242, 243). The tape 110 may
be routed through the rollers as shown in FIGS. 1 and 6. In
particular, the tape 110 may pass against a first roller 141 before
contacting the second roller 142. The second roller 142 may press
the tape 110 against the surface 155 of the module 145 thereby
causing the primary layer 115 to bond to the surface 155 of the
module 145. The backing layer 120 is then stripped away from the
primary layer 115 and fed past a third roller 143 before being
collected by a rewind roll 150 which may be rotatably mounted to a
second spindle 165 that is connected to the body 170 of the
applicator 100.
[0025] As the tape 110 passes through the rollers, adhesive residue
from the primary layer 115 may accumulate on the rollers (e.g. 141,
142). The accumulation of adhesive residue may produce undesirable
consequences. For instance, the adhesive residue may cause the
rollers (e.g. 141, 142) to bind, thereby adversely affecting tape
placement on the surface 155 of the module 145. Accurate tape
placement is vital, because the primary layer 115 may serve as an
insulating barrier within the module 145. For example, the primary
layer 115 may serve as an insulating barrier between the first and
second conductors (705, 710). Thus, poor placement of the primary
layer 115 may result in short circuiting within the module and
should therefore be avoided. Also, adhesive residue that
accumulates on the rollers (e.g. 141, 142) may be transferred to
the module, which can diminish the module's appearance as well as
decrease long-term reliability. For instance, an unwanted mass of
adhesive may create a stress concentration within the module that
promotes separation of module layers. Separation of layers is
undesirable since it may allow moisture to enter the module.
Moisture is undesirable since it can reduce the module's
performance by corroding electrical connections within the
module.
[0026] To prevent excessive accumulation of adhesive residue on the
rollers (e.g. 141, 142), the rollers must be cleaned periodically.
In previous tape applicators, cleaning was accomplished by
disassembling the applicator head 140 to access the rollers. This
process required shutting down the assembly line while the rollers
were being cleaned. As a result, productivity of the assembly line
was reduced. Also, workers were forced to balance the desire to
quickly restart the assembly line against thoroughly cleaning the
rollers. Consequently, the rollers (e.g. 141, 142) may not have
been cleaned as regularly or as thoroughly as might be
preferred.
[0027] To overcome limitations associated with existing tape
applicators, a quick release head 140 for a tape applicator 100 is
set forth. The quick release head may be rapidly removed from the
tape applicator 100 to facilitate thorough cleaning of the rollers.
For example, the quick release head 140 may be removed by hand
without the use of tools. Upon removing the head 140, a replacement
head can be quickly installed in its place. This results in minimal
downtime of the assembly line while also allowing for thorough
cleaning of the rollers within the removed head 140.
[0028] The quick release head 140 may include one or more quick
release devices configured to attach the head 140 to the tape
applicator 100, and each quick release device may include suitable
type of quick release device. For instance, the quick release
device may include a bolt 1005 secured with a cotter pin 1110 as
shown in FIG. 10. In particular, the quick release head 140 may
have a shape configured to be received by the body 170 of the tape
applicator 100. Once the head 140 is attached to the body 170, the
bolt 1005 may be inserted through a hole 1015 in the body 170 that
is aligned with a hole 1010 in the body 170. Once the bolt is
inserted through both holes, it may be secured by inserting a
cotter pin 1110 through a hole 1025 in the end of the bolt 1110.
Although a bolt and a cotter pin are described, any other suitable
retention mechanism can be used.
[0029] In another example, the quick release device may include a
first quick release skewer 480 as shown in FIGS. 4 and 5. The first
quick release skewer 480 may include a first skewer 405 attached to
a first lever 415 having a cam portion 410. As shown in FIG. 4, the
first skewer 405 may pass through a first opening 420 in a first
portion 425 of the head 140 and a second opening 435 in a second
portion 430 of the head 100. On an end opposite the cam portion
410, the skewer may be connected to a nut 440, plate, or similar
feature. The nut 440 may be captured in a slot (not shown) on the
tape applicator 100. Once inserted into the first and second
openings (420, 435) as shown in FIG. 5, actuation of the lever 415
rotates the cam portion 410 and increases the amount of clamping
force applied between the cam portion 410 and a nut 440. Therefore,
if the nut 440 is securely captured in a slot, actuation of the
lever 415 applies a force between the cam portion 410 and the nut
440 that acts to non-permanently join the first and second portions
(425, 430) of the head 140 to the body 170 of the tape applicator
100. Thus, the head 140 can be securely attached to the tape
applicator 100 simply by closing the lever 415. Similarly, the head
140 can be quickly removed from the tape applicator 100 by opening
the lever 415.
[0030] To facilitate easy cleaning of the rollers (e.g. 141, 142),
the first portion 425 and second portion 430 of the head 140 may
also be connected by a second quick release device. The second
quick release device can be any suitable quick release device. For
example, as shown in FIGS. 4 and 5, the first and second portions
(425, 430) may be connected by a second quick release skewer 485.
Similar to the first quick release skewer 480, the second quick
release skewer 485 may also include a second skewer 455 extending
between a second cam portion 450 and a second nut 460. The second
cam portion 450 may be attached to a second lever 445. During
installation, the second skewer 455 may pass through a third
opening 470 on the first portion 425 of the head 140. The second
portion 434 of the head 140 may contain a slot 465 configured to
receive the second nut 460. Actuation of the second lever 445
applies a force between the second cam portion 450 and the second
nut 460 that acts to non-permanently join the first and second
portions (425, 430) of the head 140. Thus, the first and second
portions (425, 430) can be securely joined simply by closing the
lever 445. Similarly, the first and second portions can be quickly
disassembled simply by opening the lever 445.
[0031] Alternately, the quick release device may include
interlocking features as shown in FIGS. 2 and 3. A first mating
feature 205 on the first portion 425 of the head 140 may be
configured to receive a second mating feature 210 on the second
portion 430 of the head 140 as shown in FIG. 2. The second mating
feature 210 may be configured to slide into the first mating
feature 205 as shown in FIG. 3. The second mating feature 210 may
be retained within the first mating feature 205 by friction or by a
retention device. This configuration allows for easy access to the
rollers (e.g. 141, 142) for cleaning purposes. Easy removal of the
first portion 425 of the head 140 may also be desirable when
feeding tape 110 through the rollers during setup prior to
commencing manufacturing. For example, when the tape supply roll
105 is depleted, a new supply roll 105 must be loaded onto the
first spindle 125. Once loaded, a tape end from the supply roll 105
must be fed through the rollers, and the secondary layer 120 must
be stripped from the primary layer 115 near the second roller 142.
With the first portion 425 of the head 140 removed, these tasks can
be completed much faster than with previous tape applicators,
thereby decreasing downtime and increasing productivity.
[0032] The head 140 may be attached to the body 170 of the tape
applicator 100 using interlocking features. As shown in FIGS. 2 and
3, the second portion 430 of the head 140 may include a third
mating feature 215. The third mating feature 215 may be configured
to slide into a fourth mating feature (not shown) on the body 170
of the tape applicator 100. The third mating feature 215 may be
retained within the fourth mating feature by friction or by a
retention device. This configuration allows for easy and rapid
removal of the entire quick release head 140 when cleaning is
required. Once removed, a replacement head 140 can easily and
quickly be inserted in place of the original head, and
manufacturing can resume. The original quick release head 140 can
then be disassembled and cleaned without significantly disrupting
the manufacturing process.
[0033] Although quick-release heads 140 having a first portion 425
and a second portion 430 independent from the first portion 425 are
described, this is not limiting. For example, the head 140 may
include a first portion 425 and a second portion 430 that are part
of a single structural element, as shown in FIG. 10. To clean the
rollers (e.g. 141, 142), the axles (e.g. 241, 242) may be removed
to allow for removal of the rollers. The rollers may then be
cleaned independently of the head 140. For example, the rollers may
be cleaned with solvent to remove the adhesive residue.
Alternately, the entire head may be cleaned with the rollers
attached. In one example, the head 140 may be submerged into an
ultrasonic cleaner. The cleaner may contain a solvent solution, and
the solvent solution may include surfactants and detergents capable
of removing the adhesive residue from the rollers.
[0034] The quick release head is discussed in detail above. For
completeness, it is also useful to discuss the other components of
the tape applicator 100. For instance, the tape applicator may
include supply cassette containing tape. The tape 110 may be wound
around a cylinder, spool, or other suitable core to form the supply
cassette 105. The supply cassette 105 may be rotatably mounted to
the body 170 of the tape applicator 100. To avoid jamming and to
ensure proper placement of the tape 110 on the surface 155, it is
desirable to maintain tension within the tape 110. In known
apparatuses, tension is maintained with a spring-loaded dancer arm.
Alternately, the dancer arm may be replaced by a first torque
controller installed proximate to the supply cassette 105. The
first torque controller may be installed proximate to the first hub
125 and may be capable of adjusting the resistance torque required
to rotate the supply cassette. The torque controller may be capable
of adjusting the resistance torque required to rotate the supply
cassette from about 5 N-cm to about 50 N-cm.
[0035] The supply cassette 105 may be mounted to a first hub 125
that is connected to the body 170 of the apparatus 100. The first
hub 165 may be a driven hub. For instance, the first hub 125 may
include an electric motor capable of providing torque to the first
hub 125 during the application process. The torque applied to the
first hub 125 may be controlled with a computer. The first hub 125
may include a first torque sensor. Output from the first torque
sensor may be delivered to the computer. By monitoring feedback
from the first torque sensor, the computer can adjust the torque
delivered to the first hub 125 to improve the dispensing process.
For instance, if the first torque sensor indicates that too much
torque is being applied to the first hub 125, the first hub torque
may be reduced to decrease tension in the tape 110, thereby
avoiding tape breakage and possible jamming. Alternately, if the
first torque sensor indicates that too little torque is being
applied to the first hub 125, the first hub torque may be increased
to avoid formation of slack between the supply cassette 105 and
application roller 160, which could also result in jamming.
[0036] As the supply cassette 105 is depleted during the dispensing
process, the outer diameter of the tape roll decreases. As a
result, less resistance torque is required to oppose rotation of
the hub as the mechanical advantage diminishes. Therefore, if tape
110 is being drawn from the roll at a constant force by a driven
roller, the resistance torque must be adjusted to avoid the tension
on the tape from being too high or too low. For example, if too
much resistance torque is applied to the first hub 125, too much
tension may be applied to the tape causing it to stretch or break.
Conversely, if too little resistance torque is applied to the hub,
the tape may become slack thereby causing jamming.
[0037] It may be desirable to adjust the torque applied to the hub
125 over the course of the dispensing process to account for the
changing tape roll diameter. For instance, the first torque
controller may reduce the resistance torque applied to the hub as
the roll diameter decreases over time. A first resistance torque
may be applied at a first point in time (t.sub.1), and a second
resistance torque may be applied at a second point in time
(t.sub.2), where the first resistance torque is larger than the
second resistance torque. In particular, the first resistance
torque may range from about 15 N-cm to about 50 N-cm, where t.sub.1
corresponds to a tape roll diameter ranging from about 18 cm to
about 50 cm. The second resistance torque may range from about 5
N-cm to about 15 N-cm, where t.sub.2 corresponds to a tape roll
diameter ranging from about 7 cm to about 25 cm. The resistance
torque may be adjusted linearly or nonlinearly from t.sub.1 to
t.sub.2. In addition, the resistance torque values may account for
material properties of the tape such as tensile strength. For
example, the resistance torque may be limited to avoid reaching or
exceeding the tape's tensile strength.
[0038] The tape 110 may be routed from the supply cassette 105
through one or more pre-application rollers (e.g. 130, 135). The
pre-application rollers may guide the tape 110 from the supply
cassette 105 to the quick-release head 140. The diameters of the
pre-application rollers (e.g. 130, 135) may range from about 2 mm
to about 20 mm. Preferably, the diameter of the pre-application
rollers (e.g. 130, 135) may range from about 4 mm to about 10 mm.
To ensure the tape 110 does not deviate laterally from its target
dispensing location, the pre-application rollers (e.g. 130, 135)
may have uniform diameters. Thus, by incorporating rollers having
equal diameters, tape 110 alignment may be improved. In turn,
product quality may be improved, and the dispensing rate may be
increased.
[0039] As noted above, the tape 110 may be routed from the one or
more pre-application rollers (e.g. 130, 135) to the quick-release
head 140. Once at the head 140, the primary layer 115 may be
dispensed onto the surface 155 of the photovoltaic module 145.
During operation, the head 140 may move relative to the module 145,
as shown by an arrow 195 in FIG. 1. Relative movement may result
from independent movement of the head 140 or by movement of the
body 170 to which the head 140 is connected. For example, the
apparatus 100 may be mounted on a rail system and include a drive
system which allows it to move axially. As a result, the head 140
may traverse the photovoltaic module 145 and simultaneously apply
tape 110 to its surface 155.
[0040] The quick release head 140 may provide a downward force
against the surface 155 of the module 145, and the tape 110 may be
pressed between the second roller 142 and the surface 155 of the
module 145. As the head 140 moves relative to the module 145, the
tape 110 may be drawn from the supply roller 105 and deposited on
the surface 155 of the module 145. To ensure adequate adhesion
against the surface 155 of the module 145, the apparatus 100 may
include a spring attached to the head 140 to provide downward
pressure against the tape 110 and the surface 155. Alternately, any
other suitable technique for displacing the head 140 in a downward
direction may be used. For example, pneumatic or hydraulic pressure
may be used. The diameter of the second roller 142 may range from
about 2 mm to about 20 mm. Preferably, the diameter of the second
roller 142 may range from about 4 mm to about 10 mm.
[0041] As the primary layer 115 of the tape 110 is dispensed onto
the surface'155 of the photovoltaic module 145, the backing layer
120 may be stripped from the tape 110 and routed to a rewind roll
150. The purpose of the rewind roll 150 may include collecting the
backing layer 120 during the process to avoid complications such as
jamming. The rewind roll 150 may be rotatably mounted to the body
170 of the apparatus. For example, the rewind roll 150 may be
mounted to a second hub 165 that is connected to the body 170 of
the apparatus 100. The second hub 165 may be a driven hub. For
instance, the second hub 165 may include an electric motor capable
of providing torque to the second hub and collecting the backing
layer 120 during the application process. The torque of the second
hub 165 may be controlled with a computer. The second hub 165 may
include a torque sensor. Output from the torque sensor may be
delivered to the computer. By providing feedback, the computer can
adjust the torque delivered to the second hub 165 to improve the
collection process. For instance, if the torque sensor indicates
that too much torque is being applied to the second hub 165, the
second hub torque may be reduced to decrease tension on the backing
layer 120, thereby avoiding breaking the backing layer 120 which
could result in jamming. Alternately, if the torque sensor
indicates that too little torque is being applied to the second hub
165, the second hub torque may be increased to avoid slack in the
backing layer 120 which may also cause jamming.
[0042] The apparatus 100 may include one or more post-application
rollers (e.g. 175, 180). The post-application rollers (e.g. 175,
180) may guide the backing layer 120 from the head 140 to the
rewind roll 150. The post-application rollers (e.g. 175, 180) may
have uniform diameters or non-uniform diameters. The diameters of
the post-application rollers may range from about 2 mm to about 20
mm. Preferably, the diameter of the post-application rollers may
range from about 4 mm to about 10 mm.
[0043] The apparatus 100 may include a gripper 161. The gripper 161
may be located proximate to the head 140 and may be configured to
capture the tape against one of the plurality of rollers (e.g. 141,
142) when the process stops. For instance, the computer may actuate
the gripper 161 upon stopping the dispensing process. As a result,
the gripper 161 may prevent the supply roll 105 from unraveling and
causing complications when the application process resumes. The
apparatus 100 may include more than one gripper 161, and the
grippers may be located at several locations. For example, the
apparatus may include one or gripper 161 on the supply roll side
and one gripper on the rewind roll side. In particular, a first
gripper may be configured to capture the tape 110 against the first
roller, and a second gripper may be configured to capture the
backing layer 120 against the third roller 143.
[0044] Although FIG. 1 depicts a dynamic head 140 and a stationary
photovoltaic module 145, this is not limiting. For instance, during
manufacturing, the head 140 may remain stationary and the module
145 may move relative to the head 140. The tape applicator 100 may
be positioned near, or connected to, a conveyor system. The
conveyor system may include a conveyor surface and a drive
mechanism for propelling the conveyor surface. The drive mechanism
may include, for example, an electric motor and gear assembly
capable of transmitting motion to the conveyor surface. The
conveyor surface may include a belt, roller, cart, trolley, chain,
screw, or any other suitable device for advancing the module 145. A
conveyor speed sensor may monitor the speed of the conveyor
surface. During manufacturing, the module 145 may be loaded onto
the conveyor surface, and the drive mechanism may be activated. The
photovoltaic module 145 may travel on the conveyor surface and pass
beneath the head 140, and the head 140 may dispense tape onto the
surface 155 of the module 145. Although the previous examples
describe a stationary applicator paired with a dynamic module and a
dynamic applicator paired with a stationary module, this is not
limiting. For example, during manufacturing, the head 140 and the
photovoltaic module 145 may both move relative to the other.
[0045] The applicator 100 may include a sensor 193 to detect the
presence of tape 110. The sensor may be any suitable sensor such
as, for example, a proximity sensor or a photoeye. The sensor may
be configured to detect the presence of tape 110 and provide a
signal to the computer. If the tape 110 breaks, or if the supply
cassette 105 is depleted of tape 110, the sensor 193 will no longer
detect the tape's presence. As a result, the signal being conveyed
from the sensor 193 to the computer will change. The computer can
respond to the change in signal by, for example, stopping the
dispensing process. By stopping the process, the apparatus may
avoid producing scrap modules that necessitate rework.
[0046] The rate at which the tape 110 is dispensed may be monitored
by a speed sensor 192. The speed sensor 192 may be connected to the
body 170 of the tape applicator 100. The speed sensor 192 may
monitor the dispensing rate by monitoring the linear speed of the
tape as it passes the sensor 192. Alternately, the sensor 192 can
monitor the rotational speed of either the supply or rewind roller,
and dispensing speed can be calculated if roll diameter is known.
By multiplying the rotational speed of the roller by the
circumference of the roller, the dispensing speed can be
calculated. By monitoring the dispensing rate, depletion of the
supply cassette 105 can be anticipated and the process can be
suspended at an appropriate time to allow for replacement of the
empty supply roll 105 with a full roll. The quantity of tape
remaining on the supply roll 105 may also be monitored with a
stroke counter.
[0047] To facilitate real-time calculation and monitoring of the
dispensing rate, the output of the speed sensor 192 may be
delivered to the computer. To ensure the primary layer 115 is being
dispensed in the correct position on the surface of the module 145,
the tape applicator 100 may include a machine vision system (not
shown) which monitors the position of the tape in a direction
normal to the direction of conveyor movement. The vision system may
include a Charge Coupled Device (CCD) camera and image processing
software. The computer may be configured to simultaneously receive
and process signals from multiple inputs such as, for example, the
speed sensor 192, conveyor speed sensor 191, and vision system. The
computer may include a data acquisition board capable of converting
analog signals to digital signals. The computer may monitor,
record, and store signal data in a database. Data recorded during
the manufacture of the module may be recorded and assigned to that
module in the database. Therefore, if a performance issue
subsequently arises after the module is deployed in the field, the
manufacturing data associated with that module can be reviewed to
determine the root cause of the issue.
[0048] The computer may include a software program that permits
execution of one or more manufacturing processes. For instance, the
software may enable application of tape 110 with little or no
manual input. A user may place a partially completed module 145
onto the conveyor surface and initiate a program which
automatically applies tape 110 as defined in the manufacturing
process. The software program may enable display of a graphical
user interface (GUI) on a monitor associated with the computer. The
GUI may allow a user to input target manufacturing parameters such
as conveyor speed, dispensing rate, resistance torques. The GUI may
display data acquired from the sensors in real-time while the
manufacturing process is running. In addition, the GUI may allow
the user to recall test data from the database and create, display,
and print charts and graphs generated from the stored data.
[0049] The tape applicator 100 may include a cutter 181 configured
to sever the tape or one of the tape's layers. The cutter 181 may
be attached to the body 170 of the tape applicator 100.
Alternately, the cutter 181 may be attached to the head 140. Any
suitable method of actuating the cutter 181 may be employed, such
as actuation via pneumatic, hydraulic, or electronic methods. For
example, the cutter may be an air knife that is pneumatically
actuated.
[0050] During manufacturing, the cutter 181 may be activated after
the proper amount of tape 110 has been dispensed. For instance,
based on input parameters, sensotsignals, and software code, the
computer may detect when the proper amount of tape 110 has been
dispensed for a given module. At this moment, the computer may
actuate the cutter 181, thereby severing the tape 110. Alternately,
at the end of an application cycle, the body 170 may move away the
surface 155 of the module 145 so that the tape 110 is brought in
close proximity to the cutter 181. As a result, the tape 110 may be
lifted against the cutter 181, and the forward movement of the head
140 may advance the cutter 181 through the tape 110, which may
already be adhered to the module 145 and, therefore, fixed at one
point.
[0051] In one aspect, a quick release head for a double sided tape
applicator may include a first portion, a second portion
substantially parallel to the first portion, a plurality of rollers
positioned between the first and second portions, and a first quick
release device allowing attachment or removal of the head to or
from a double sided tape applicator. The quick release head may
include a second quick release device allowing attachment or
removal of the first portion to or from the second portion. The
plurality of rollers may include a first roller mounted on a first
axle, a second roller mounted on a second axle, and a third roller
mounted on a third axle, where the first, second, and third axles
extend from the first portion to the second portion. The first
quick release device may be a quick release skewer. Similarly, the
second quick release device is a quick release skewer. Alternately,
the first quick release device may include a mating feature on the
tape applicator head configured to interlock with a mating feature
on the tape applicator. Similarly, the second quick release device
may include a mating feature on the first portion configured to
interlock with a mating feature on the second portion. The tape
applicator may include a cutter mounted to the head, where the
cutter is configured to sever tape proximate to the plurality of
rollers. The cutter may be a pneumatically actuated blade.
[0052] In another aspect, a double sided tape applicator may
include a body, a first spindle attached to the body and configured
to receive a supply roll, a second spindle attached to the body and
configured to receive a rewind roll, and a quick release head
attached to the body by a first quick release device. The first
quick release device may be a quick release skewer. Alternately,
the first quick release device may include a mating feature on the
quick release head configured to interlock with a mating feature on
the body. The quick release head may include a first portion, a
second portion substantially parallel to the first portion, and a
plurality of rollers positioned between the first and second
portions. The tape applicator head may further include a second
quick release device allowing attachment or removal of the first
portion to or from the second portion. The plurality of rollers may
include a first roller mounted on a first axle, a second roller
mounted on a second axle, and a third roller mounted on a third
axle, where the first, second, and third axles extend from the
first portion to the second portion. The tape applicator may also
include a cutter mounted to the head, where the cutter is
configured to sever tape routed through the plurality of rollers.
Alternately, the tape applicator may include a cutter mounted to
the body.
[0053] In yet another aspect, a method for manufacturing a
photovoltaic module may include forming a first section of
conductor adjacent to a partially completed photovoltaic module,
applying double sided tape adjacent to the first section of
conductor with a tape applicator comprising a first quick release
head, and forming a second section of conductor adjacent to the
double sided tape. The method may also include removing the first
quick release head from the tape applicator by actuating a first
quick release device, and attaching a second quick release head to
the tape applicator by actuating a first quick release device. The
method may further include cleaning the first quick release head
while the second quick release head is attached to the tape
applicator, and subsequently removing the second quick release head
from the tape applicator and re-attaching the first quick release
head to the tape applicator.
[0054] In another aspect, a method for manufacturing a photovoltaic
module may include applying double sided tape adjacent to a
partially completed photovoltaic module with a tape applicator
comprising a first quick release head. The method may also include
forming a conductor adjacent to the double sided tape. The method
may include removing the first quick release head from the tape
applicator by actuating a first quick release device and attaching
a second quick release head to the tape applicator by actuating a
first quick release device. The method may include cleaning the
first quick release head while the second quick release head is
attached to the tape applicator and subsequently removing the
second quick release head from the tape applicator and re-attaching
the first quick release head to the tape applicator.
[0055] Details of one or more embodiments are set forth in the
accompanying drawings and description. Other features, objects, and
advantages will be apparent from the description, drawings, and
claims. Although a number of embodiments of the invention have been
described, it will be understood that various modifications may be
made without departing from the spirit and scope of the invention.
It should also be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various features and basic principles of the
invention.
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