Systems, methods and apparatus for electroplating photovoltaic cells

Patent metadata

Field	Value
Publication number	US-10301740-B2
Application number	US-201514983301-A
Country	US
Kind code	B2
Filing date	Dec 29, 2015
Priority date	Dec 14, 2015
Publication date	May 28, 2019
Grant date	May 28, 2019

Abstract

A two piece electroplating frame or electroplating frame is disclosed that is suitable for holding multiple solar cells during an electroplating operation. The electroplating frame can be formed from or at least covered with non-conductive material to reduce the collection of plating material on the electroplating frame. The two pieces of the electroplating frame can be coupled together around the solar cells by magnets distributed throughout the electroplating frame. The electroplating frame can include alignment features for self-aligning the assembly of the two pieces without requiring precise pre-alignment.

First claim

What is claimed is:

1. An electroplating frame for supporting a plurality of solar cells during a manufacturing operation, the electroplating frame comprising:
a first frame defining a plurality of pockets, each of the pockets having a shape and size suitable for supporting one of the plurality of solar cells;
a second frame;
a first plurality of magnetic fasteners distributed within the first frame;
a second plurality of magnetic fasteners distributed within the second frame, each magnetic fastener of the first and second plurality of magnetic fasteners comprising a magnet and a casing, magnetic forces between the first and second plurality of magnetic fasteners being configured to secure the first and second frames together by applying the magnetic forces to the first and second frames through the casings of the first and second plurality of magnetic fasteners to compress the first and second frames between the first and second plurality of magnetic fasteners.

2. The electroplating frame of claim 1 , further comprising:
a plurality of hard stops configured to establish a minimum interval between the first and second frames when the frames are secured together.

3. The electroplating frame of claim 2 , wherein the plurality of hard stops prevent the first plurality of magnetic fasteners within the first frame from directly contacting the second plurality of magnetic fasteners within the second frame.

4. The electroplating frame of claim 1 , wherein the first plurality of magnetic fasteners within the first frame are arranged in the same pattern as the second plurality of magnetic fasteners in the second frame.

5. The electroplating frame of claim 1 , wherein the first frame comprises a plurality of support structures distributed about a periphery of each of the pockets that are configured to support the solar cells within the pockets.

6. The electroplating frame of claim 1 , wherein the second frame comprises a plurality of carrying handles disposed proximate each of the magnets distributed within the second frame.

7. The electroplating frame of claim 6 , wherein the plurality of carrying handles each include an opening configured to receive a portion of a robotic arm for manipulating the second frame.

8. The electroplating frame of claim 1 , wherein the first and second frames comprise electrically conductive cores surrounded by a protective layer of electrically insulating material.

9. An electroplating frame suitable for supporting a plurality of solar cells during a manufacturing operation, comprising:
a first frame comprising a first plurality of magnetic fasteners extending through a first plurality of openings defined by the first frame, the first plurality of openings being arranged in a first pattern; and
a second frame comprising a second plurality of magnetic fasteners extending through a second plurality of openings defined by the second frame, the second plurality of openings being arranged in a second pattern complementary to the first pattern, a magnetic force between the first and second plurality of magnetic fasteners being configured to secure the first and second frames together by compressing the first and second frames between the first and second plurality of magnetic fasteners,
wherein the first and second frames cooperate to define a plurality of locations within the electroplating frame when compressed together by the first and second plurality of magnetic fasteners, each of the locations having a size and shape suitable for accommodating a solar cell of the plurality of solar cells.

10. The electroplating frame of claim 9 , further comprising:
a plurality of alignment features coupled with the second frame and having sloped ends that engage tapered openings defined by lateral walls of the first frame when the first and second frames are being magnetically coupled together, the interaction between the plurality of alignment features and the lateral walls of the first frame refining an alignment between the first and second frames.

11. The electroplating frame of claim 10 , wherein the first frame further comprises a plurality of electroplating pins distributed around a periphery of the plurality of locations, the plurality of electroplating pins configured to compress portions of each of the plurality of solar cells against the second frame to prevent movement of the plurality of solar cells during reorientation of the electroplating frame.

12. The electroplating frame of claim 11 , wherein the plurality of electroplating pins define conductive pathways configured to deliver electrical energy to the plurality of solar cells during an electroplating operation.

13. The electroplating frame of claim 11 , wherein the electroplating pins comprise spring loaded pins positioned within a corresponding aperture by a support structure extending from a lateral wall of the first frame.

14. The electroplating frame of claim 9 , wherein each magnetic fastener of the first and second plurality of magnetic fasteners comprises a permanent magnet disposed within a magnet enclosure.

Assignees

• Solarcity Corp

Inventors

• Gonzalez Pablo
• Kang Ming-Du

Classifications

• H10P14/47

  Electrolytic deposition, i.e. electroplating; Electroless plating · CPC title

• H01L31/022458

  Electricity · mapped topic

• C25D5/02

  Electroplating of selected surface areas · CPC title

• C25D7/126 Primary

  for solar cells · CPC title

• C25D17/08

  Supporting} racks {, i.e. not for suspending · CPC title