Conductive wire production device and method for preparing solar cell

Abstract

Provided in the present application are a conductive wire production device and a method for preparing a solar cell. The conductive wire production device comprises: a first channel, which has a first feed inlet and a first discharge outlet, wherein the first channel allows a filamentary conductor to enter via the first feed inlet and to be discharged via the first discharge outlet; and second channels, which have second feed inlets and second discharge outlets, wherein the second discharge outlets surround the first discharge outlet, the second channels allow cladding materials to enter via the second feed inlets and to be discharged via the second discharge outlets, and the cladding materials discharged from the second discharge outlets cover the outer peripheral surface of the filamentary conductor. The conductive wire of the present application has the advantages of a low cost and a small width.

Description

Conductive wire production equipment and solar cell manufacturing method Technical Field

[0001] This invention relates to a conductive wire production apparatus and a method for preparing solar cells. Background Technology

[0002] In solar cells, grid lines serve to conduct current. Methods for fabricating grid lines include electroplating and screen printing. Electroplating involves complex processes and expensive equipment, while screen-printed grid lines tend to be wider. Reducing the manufacturing cost and width of grid lines is a key research direction in this field. Summary of the Invention

[0003] The technical problem to be solved by this application is to provide a conductive wire production apparatus and a method for preparing a solar cell, wherein the conductive wires in the conductive wire production apparatus and the method for preparing a solar cell have the advantages of low cost and small width.

[0004] To address the aforementioned technical problems, this application provides a conductive wire production apparatus, comprising: a first channel having a first inlet and a first outlet, wherein the first channel allows a filamentous conductor to enter through the first inlet and exit through the first outlet; and a second channel having a second inlet and a second outlet, wherein the second outlet surrounds the first outlet, and the second channel allows a coating material to enter through the second inlet and exit through the second outlet, wherein the coating material exiting through the second outlet covers the outer peripheral surface of the filamentous conductor.

[0005] In one embodiment of this application, the second channel includes two independent sub-channels, the second feed port includes two independent sub-feed ports, and the second discharge port includes two independent sub-discharge ports. Each sub-channel is connected to the corresponding sub-feed port and sub-discharge port.

[0006] In one embodiment of this application, the first discharge port is triangular, one of the two sub-discharge ports is adjacent to one side of the triangle, and the other of the two sub-discharge ports is adjacent to the other two sides of the triangle.

[0007] In one embodiment of this application, the first discharge port is triangular, circular, elliptical, or trapezoidal.

[0008] In one embodiment of this application, the coating material is a conductive paste or powdered metal particles. When the coating material is powdered metal particles, the conductive wire production device has the function of heating and melting the powdered metal particles.

[0009] In one embodiment of this application, the conductive wire production apparatus further includes a first filament conductor feeding unit, which includes a crucible, a heating device, and a forming device. The crucible is used to hold the raw material for preparing the filament conductor, the heating device is used to heat the raw material, and the forming device is connected to the crucible. The forming device is used to cool the raw material and process the raw material into a filament conductor with a predetermined cross-section.

[0010] In one embodiment of this application, the conductive wire production apparatus further includes a second filamentary conductor feeding unit, the second filamentary conductor feeding unit having a through hole with an inlet and an outlet, the cross-section of the through hole gradually changing from the inlet to the outlet.

[0011] In one embodiment of this application, the conductive wire production apparatus further includes a coating material feeding system, which is connected to a second feed port, wherein the coating material feeding system is used to provide the coating material to the second channel.

[0012] This application also proposes a method for fabricating a solar cell, comprising: providing a filamentous conductor to the first channel through a first inlet, and discharging the filamentous conductor from a first outlet of the first channel; providing a coating material to the second channel through a second inlet, the second channel having a second outlet surrounding the first outlet, such that the coating material is discharged through the second outlet and covers the outer periphery of the filamentous conductor to form a conductive wire comprising the filamentous conductor and the coating material covering the outer periphery of the filamentous conductor; and laying the conductive wire on a solar cell intermediate, heating the conductive wire to bond the conductive wire to the solar cell intermediate, wherein the conductive wire is electrically connected to the solar cell intermediate.

[0013] In one embodiment of this application, the second channel includes two independent sub-channels, the second feed port includes two independent sub-feed ports, and the second discharge port includes two independent sub-discharge ports. Each sub-channel is connected to the corresponding sub-feed port and sub-discharge port, and different covering materials are provided to the two sub-channels. The different covering materials cover a designated area on the outer periphery of the filamentous conductor.

[0014] In one embodiment of this application, the cross-section of the filamentous conductor discharged through the first outlet is triangular, and different covering materials cover one side and the other two sides of the filamentous conductor respectively.

[0015] In one embodiment of this application, the filamentous conductor is a metal wire comprising one or more of copper, silver, aluminum, and tin.

[0016] In one embodiment of this application, the step of laying the conductive wire on the solar cell intermediate includes: laying the conductive wire on the solar cell intermediate through the first discharge port and the second discharge port.

[0017] In one embodiment of this application, the method for heating the conductive wire includes: laser heating and drying heating.

[0018] In one embodiment of this application, the step of laying the conductive wire on the solar cell intermediate includes: embedding at least a portion of the conductive wire into an adhesive film, and placing the adhesive film with the embedded conductive wire on the solar cell intermediate.

[0019] In one embodiment of this application, the method for heating the conductive wire includes heating the conductive wire during the process of pressing the adhesive film using a hot pressing process.

[0020] In one embodiment of this application, the method for preparing a solar cell further includes: before placing the adhesive film with embedded conductive wires on the solar cell intermediate, a layer of conductive paste is disposed on the surface of the conductive wires in contact with the solar cell intermediate, wherein the conductive wires are completely embedded in the adhesive film and the top surface of the conductive wires is lower than the top surface of the adhesive film.

[0021] In one embodiment of this application, the step of laying the conductive wire on the solar cell intermediate includes: embedding the conductive wire into an adhesive film, depositing a layer of conductive paste on the surface of the conductive wire in contact with the solar cell intermediate, and transferring the conductive wire onto the solar cell intermediate.

[0022] In one embodiment of this application, the solar cell intermediate includes a transparent conductive layer, the conductive wire is laid on the transparent conductive layer, and the conductive wire is heated to bond the conductive wire to the transparent conductive layer, wherein the conductive wire is electrically connected to the transparent conductive layer.

[0023] In one embodiment of this application, the solar cell intermediate includes a doped layer, a dielectric layer, and a plurality of metal contacts. The dielectric layer is located above the doped layer, and the plurality of metal contacts pass through the dielectric layer and are electrically connected to the doped layer. The conductive wire is laid on the dielectric layer, and the conductive wire is heated to bond it to the dielectric layer and the plurality of metal contacts, thus electrically connecting the conductive wire to the plurality of metal contacts.

[0024] Compared with the prior art, this application has the following advantages: Because this application prepares conductive lines by covering a filamentous conductor with a coating material, the width of the conductive lines in this application is smaller than that of the grid lines produced by screen printing. Furthermore, the conductive line production apparatus of this application is less expensive than the equipment used in electroplating processes.

[0025] Overview of the attached figures

[0026] The features and performance of the present invention are further described by the following embodiments and accompanying drawings.

[0027] Figure 1 is a cross-sectional schematic diagram of a conductive wire production apparatus according to an embodiment of this application;

[0028] Figure 2 is a schematic diagram of the first discharge port and the second discharge port in one embodiment of this application;

[0029] Figure 3 is a perspective view of a conductive wire production apparatus according to an embodiment of this application;

[0030] Figure 4 is a schematic cross-sectional view of a conductive wire in one embodiment of this application;

[0031] Figure 5 is a schematic diagram of the first discharge port and the second discharge port in one embodiment of this application;

[0032] Figure 6 is a cross-sectional schematic diagram of the conductive wire in another embodiment of this application;

[0033] Figures 7 and 8 are schematic diagrams of the structure of a filamentary conductor feed unit in one embodiment of this application;

[0034] Figures 9 and 10 are schematic diagrams of the structure of the filamentary conductor feed unit in another embodiment of this application;

[0035] Figure 11 is a schematic flowchart of a method for preparing a solar cell according to an embodiment of this application;

[0036] Figures 12 to 14 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in one embodiment of this application;

[0037] Figures 15 to 18 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in another embodiment of this application;

[0038] Figures 19 to 21 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in another embodiment of this application;

[0039] Figures 22 and 23 are schematic diagrams of the electrical connection between the conductive wire and the solar cell intermediate in one embodiment of this application;

[0040] Figures 24 and 25 are schematic diagrams of the electrical connection between the conductive wire and the solar cell intermediate in another embodiment of this application.

[0041] Preferred embodiments of the present invention

[0042] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of this application. For those skilled in the art, these drawings can be applied to other similar scenarios without creative effort. Unless obvious from the context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.

[0043] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0044] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of this application. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0045] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0046] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0047] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application. In addition, although the terminology used in this application is selected from commonly known and used terms, some terms mentioned in this application's specification may have been chosen by the applicant according to his or her judgment, and their detailed meanings are explained in the relevant sections of this description. Moreover, this application should be understood not only through the actual terms used, but also through the meaning implied by each term.

[0048] Flowcharts are used in this application to illustrate the operations performed by the system according to embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, various steps can be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0049] The conductive wire production apparatus and the method for preparing solar cells of this application will be described below through examples.

[0050] Referring to Figures 1 and 2, the conductive wire production apparatus includes a first channel 110 and a second channel 120. The first channel 110 has a communicating first inlet 111 and a first outlet 112, allowing the filamentous conductor 130 to enter through the first inlet 111 and exit through the first outlet 112. The second channel 120 has a communicating second inlet 121 and a second outlet 122, allowing a coating material 140 to enter through the second inlet 121 and exit through the second outlet 122. The second outlet 122 surrounds the first outlet 112, so that the coating material 140 exiting through the second outlet 122 can cover the outer peripheral surface of the filamentous conductor 130. "The second discharge port 122 surrounds the first discharge port 112" means that the second discharge port 122 completely surrounds the first discharge port 112 (as shown in Figure 2). It should be noted that "the second discharge port 122 basically surrounds the first discharge port 112" is also within the scope of protection of this application.

[0051] Referring to Figures 2 and 3, the first discharge port 112 is triangular, but it can also be circular, elliptical, or trapezoidal. The second discharge port 122 is a closed ring surrounding the first discharge port 112. After the covering material 140 is discharged through the second discharge port 122, it can cover the outer circumference of the filamentous conductor 130. The second discharge port 122 can also be other shapes.

[0052] In Figure 3, the cross-section of the filamentary conductor 130 is triangular. However, the cross-section of the filamentary conductor 130 can also be other shapes, such as circular, elliptical, rectangular, or trapezoidal. The first channel 110 can have a shaping function. Specifically, for a filamentary conductor 130 with a cross-sectional shape different from that of the first outlet 112, during the process of the filamentary conductor 130 moving from the first inlet 111 to the first outlet 112, the first channel 110 can ensure that the cross-sectional shape of the filamentary conductor 130 is the same as that of the first outlet 112 when it is discharged. The first channel 110 can achieve the above-mentioned shaping function by gradually changing its cross-sectional shape.

[0053] The filamentary conductor 130 may be one or more metal wires including silver, copper, aluminum, and tin.

[0054] The coating material 140 possesses a certain degree of fluidity and adhesiveness upon exiting the second outlet 122, enabling it to adhere to the filamentous conductor 130. After the coating material 140 cools and solidifies, it can regain its fluidity and adhesiveness through heating. The coating material 140 can be a conductive paste used in conventional techniques for preparing solar cell grid lines, and the conductive paste may include one or more of silver particles, copper particles, aluminum particles, and tin particles. The coating material 140 can also be powdered metal particles. In this case, the conductive wire production device has a heating function to heat and melt the powdered metal particles, and the molten powdered metal particles are discharged through the second outlet 122 and cover the outer peripheral surface of the filamentous conductor 130.

[0055] Referring to Figures 3 and 4, the conductive wire 150 prepared by the conductive wire production apparatus includes a substrate 151 and a covering layer 152, with the covering layer 152 covering the outer peripheral surface of the substrate 151. It can be understood that the substrate 151 is formed of a filamentous conductor 130, and the covering layer 152 is formed of a covering material 140. Referring to Figures 1 and 4, the conductive wire production apparatus can lay the conductive wire 150 on a solar cell intermediate 160, and can heat the conductive wire 150 to bond it to the solar cell intermediate 160 and to form an electrical connection with it. Heating also has the function of curing the covering layer 152.

[0056] The width of the conductive line 150 can be controlled by adjusting the size of the filament conductor 130 and the thickness of the covering material 140. "Width" refers to the width of the projection of the conductive line 150 onto the solar cell intermediate 160 along a direction perpendicular to the solar cell intermediate 160. Because this application prepares the conductive line 150 by covering the filament conductor 130 with the covering material 140, the width of the conductive line 150 prepared in this application is smaller than that of the grid lines produced by screen printing. Furthermore, compared to the equipment used in electroplating processes, the conductive line production apparatus of this application has a lower cost.

[0057] Referring to Figure 5, the second channel includes two independent sub-channels, the second inlet includes two independent sub-inlets, and the second outlet 122 includes two independent sub-outlets 122a and 122b. Each sub-channel connects to its corresponding sub-inlet and sub-outlet, and the sub-outlets 122a and 122b are distributed around the first outlet 112. The two sub-channels in the second channel are not connected to each other, and two different coating materials can be provided to the two sub-channels. These two different coating materials are discharged from the sub-outlets 122a and 122b respectively, thereby coating different coating materials onto a designated area on the outer peripheral surface of the filamentary conductor 130.

[0058] Referring again to Figure 5, the first outlet 112 is triangular, with sub-outlets 122a adjacent to the base of the triangle and sub-outlets 122b adjacent to two sides of the triangle. The coating material discharged from sub-outlet 122a covers one side of the filamentous conductor, and the coating material discharged from sub-outlet 122b covers the other two sides of the filamentous conductor. Referring to Figure 6, thanks to the design of the two independent sub-channels, for the conductive wire 150 with a triangular cross-section, a first coating layer 153 that facilitates electrical connection with the solar cell intermediate 160 can be formed on the side of the conductive wire 150 that contacts the solar cell intermediate 160. A highly reflective second coating layer 154 is formed on the other two sides. The second coating layer 154 can reflect incident light back to the solar cell intermediate 160, thereby improving the utilization rate of incident light by the solar cell.

[0059] Referring to Figure 1, in one embodiment, the first channel 110 extends along a straight line, and the cross-section (horizontal section) of the second channel 120 at any position in the vertical direction is a closed shape (e.g., annular) and surrounds the first channel 110.

[0060] Referring to Figures 7 and 8, in one embodiment, the conductive wire production apparatus further includes a first filament conductor feeding unit 170. The first filament conductor feeding unit 170 has a crucible 171, a heating device 172, and a forming device 173. The crucible 171 is used to hold the raw material for preparing the filament conductor 130. The heating device 172 is used to heat and melt the raw material in the crucible 171. The forming device 173 is connected to the crucible 171 and is used to cool the raw material and process it into a filament conductor 130 with a predetermined cross-section. In the embodiment of Figure 7, the heating device 172 is a heating wire surrounding the crucible 171. The heating device 172 in this application is not limited to a heating wire; it can also be any other heating device capable of heating and melting the raw material in the crucible 171. The forming device 173 has a cooling function and also has an outlet 173a with a predetermined cross-sectional shape. As the molten raw material flows through the forming device 173, the forming device 173 cools and processes the molten raw material into a filament conductor 130 with a predetermined cross-section. In Figure 8, the predetermined cross-section is a triangle (it can be understood that the outlet 173a is also a triangle). The predetermined cross-section can also be other shapes, such as circles, ellipses, rectangles or trapezoids, etc.

[0061] The first filamentary conductor feeding unit 170 can supply the prepared filamentary conductor 130 into the first channel 110 through the first feed port 111.

[0062] Referring to Figures 9 and 10, in one embodiment, the conductive wire production apparatus further includes a second filament conductor feeding unit 180. The second filament conductor feeding unit 180 has a through-hole with an inlet 181 and an outlet 182, the cross-section of which gradually changes from the inlet 181 to the outlet 182. Thus, the through-hole can compress the metal wire fed in through the inlet 181 into a filament conductor with a triangular cross-section. In the embodiments of Figures 9 and 10, the predetermined cross-section is triangular, but the predetermined cross-section can also be other shapes, such as circular, elliptical, rectangular, or trapezoidal.

[0063] The filament conductor 130 prepared by the second filament conductor feeding unit 180 can enter the first channel 110 through the first feed port 111.

[0064] In one embodiment, the conductive wire production apparatus further includes a coating material feeding system connected to a second feed port, the coating material feeding system being used to provide coating material to the second channel.

[0065] In another aspect, this application also proposes a method for preparing a solar cell. Referring to Figure 11, the method for preparing a solar cell includes the following steps S210 to S230.

[0066] Step S210: A filamentous conductor is supplied to the first channel from the first inlet and discharged from the first outlet of the first channel;

[0067] Step S220: A coating material is supplied to the second channel from the second inlet of the second channel. The second channel has a second outlet surrounding the first outlet, so that the coating material is discharged through the second outlet and covers the outer peripheral surface of the filamentous conductor to form a conductive wire including the filamentous conductor and the coating material covering the outer peripheral surface of the filamentous conductor.

[0068] Step S230: Lay the conductive wire on the solar cell intermediate and heat the conductive wire to bond it to the solar cell intermediate, wherein the conductive wire is electrically connected to the solar cell intermediate.

[0069] The following describes steps S210 to S230 in detail.

[0070] Referring to Figure 1, in step S210, a filamentous conductor 130 is supplied to the first channel 110 through the first feed port 111, and the filamentous conductor 130 is discharged from the first discharge port 112 of the first channel 110. The filamentous conductor 130 can be prepared and supplied to the first channel 110 using the filamentous conductor feeding unit shown in Figures 7 and 9.

[0071] Referring to Figures 1 to 4, in step S220, a coating material 140 is provided to the second channel 120 through the second inlet 121. The second channel 120 has a second outlet 122 surrounding the first outlet 112, so that the coating material 140 is discharged through the second outlet 122 and covers the outer peripheral surface of the filamentous conductor 130 to form a conductive wire 150 including the filamentous conductor 130 and the coating material 140. The coating material 140 covers the outer peripheral surface of the filamentous conductor 130, wherein the filamentous conductor 130 constitutes the base 151 of the conductive wire 150, and the coating material 140 constitutes the coating layer 152 of the conductive wire 150.

[0072] Referring to Figure 5, in one embodiment, the second channel includes two independent sub-channels, the second inlet includes two independent sub-inlets, and the second outlet 122 includes two independent sub-outlets 122a. Each sub-channel connects to its corresponding sub-inlet and sub-outlet 122a and 122b, which are distributed around the first outlet 112. The two sub-channels are not connected to each other. Two different coating materials are provided to the two sub-channels, and these two different coating materials are discharged from the sub-outlets 122a and 122b, respectively, thereby allowing different coating materials to be coated on designated areas of the outer peripheral surface of the filamentary conductor 130.

[0073] Referring again to Figure 5, the first outlet 112 is triangular, and the cross-section of the filamentous conductor discharged through the first outlet 112 is also triangular (the outer circumference of the filamentous conductor has three sides). The sub-outlet 122a is adjacent to the base of the triangle, and the sub-outlet 122b is adjacent to two sides of the triangle. The coating material discharged from the sub-outlet 122a covers one side of the filamentous conductor, and the coating material discharged from the sub-outlet 122b covers the other two sides of the filamentous conductor.

[0074] In one embodiment, the filamentary conductor 130 may be a metal wire comprising one or more of silver, copper, aluminum, and tin.

[0075] Referring to Figure 1, in step S230, conductive wires 150 are laid on the solar cell intermediate 160, and the conductive wires 150 are heated to bond them to the solar cell intermediate 160, thus forming an electrical connection. The solar cell intermediate 160 refers to a solar cell that has not yet been metallized (i.e., a solar cell without grid lines). After the conductive wires 150 are electrically connected to the solar cell intermediate 160, the solar cell intermediate 160 is processed into a normally functioning solar cell. The conductive wires 150 can collect the current in the solar cell and conduct the current to the outside.

[0076] Referring to Figure 1, in one embodiment, the step of laying the conductive wire 150 on the solar cell intermediate 160 includes: laying the conductive wire 150 directly on the solar cell intermediate 160 through the first discharge port 112 and the second discharge port 122, and heating the conductive wire 150 includes: using laser heating or drying heating.

[0077] Figures 12 to 14 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in one embodiment. Referring to Figures 12 to 14, the step of laying the conductive wire 150 on the solar cell intermediate 160 includes: embedding at least a portion of the conductive wire 150 into the adhesive film 190, and then placing the adhesive film 190 on the solar cell intermediate 160, wherein the side containing the conductive wire 150 faces the solar cell intermediate 160. The adhesive film 190 can be an adhesive film used in conventional techniques for preparing solar cell laminates. The method of heating the conductive wire 150 includes heating the conductive wire 150 during the hot pressing process of bonding the adhesive film 190. More specifically, in the process of preparing the solar cell laminate, the adhesive film 190 is placed on the solar cell intermediate 160, glass 210 is placed on the adhesive film 190, and the solar cell intermediate 160, the adhesive film 190, and the glass 210 are bonded together by a hot pressing process. As shown in Figure 14, during the hot pressing process, the coating layer in the conductive wire 150 is heated and melted. The heated and melted coating layer is bonded together with the solar cell intermediate 160 and forms an electrical connection.

[0078] Figures 15 to 18 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in another embodiment. First, referring to Figures 15 and 16, the step of laying the conductive wire 150 on the solar cell intermediate 160 includes: completely embedding the conductive wire 150 into the adhesive film 190, with the top surface of the conductive wire 150 lower than the top surface of the adhesive film 190; before placing the adhesive film 190 on the solar cell intermediate 160, a layer of conductive paste 220 is applied to the top surface of the conductive wire 150. The conductive paste 220 can be a paste containing one or more of silver particles, copper particles, aluminum particles, and tin particles. Next, referring to Figures 16 to 18, the adhesive film 190 in Figure 16 is placed on both sides of the solar cell intermediate 160, with the side containing the conductive paste 220 facing the solar cell intermediate 160; glass 210 is placed on the adhesive film 190; and the solar cell intermediate 160, the adhesive film 190, and the glass 210 are pressed together using a hot-pressing process. During the hot pressing process, the conductive paste 220 bonds to the solar cell intermediate 160, forming an electrical connection. In cases where the coating layer 152 in the conductive wire 150 cannot melt during the hot pressing process, the conductive paste 220 helps to ensure a stable and reliable bond and electrical connection between the conductive wire 150 and the solar cell intermediate 160.

[0079] Figures 19 to 21 are schematic diagrams illustrating the process of forming an electrical connection between the conductive wire and the solar cell intermediate in another embodiment. Referring to Figures 19 to 21, the conductive wire 150 is embedded in the adhesive film 190, a layer of conductive paste 220 is applied to the surface where the conductive wire 150 contacts the solar cell intermediate 160, and the conductive wire 150 is transferred onto the solar cell intermediate 160, thus forming an electrical connection between the conductive wire 150 and the solar cell intermediate 160. The transfer process includes placing the adhesive film 190 with the embedded conductive wire 150 on the solar cell intermediate 160, contacting the conductive paste 220 with the solar cell intermediate 160, heating the conductive wire 150 and the conductive paste 220, connecting the conductive paste 220 to the solar cell intermediate 160, and then removing the adhesive film 190.

[0080] Figures 22 and 23 are schematic diagrams of the electrical connection between the conductive wire and the solar cell intermediate in one embodiment. Figure 23 is a cross-sectional view along line AA in Figure 22. Referring to Figures 22 and 23, the solar cell intermediate 160 includes a transparent conductive layer 161. A conductive wire 150 is laid on the transparent conductive layer 161. The conductive wire 150 is heated to bond it to the transparent conductive layer 161, thus electrically connecting the conductive wire 150 to the transparent conductive layer 161.

[0081] Figures 24 and 25 are schematic diagrams of the electrical connection between the conductive wire and the solar cell intermediate in another embodiment. Figure 25 is a cross-sectional view along line BB of Figure 24. Referring to Figures 24 and 25, the solar cell intermediate includes a doped layer 162, a dielectric layer 163, and multiple metal contacts 164. The doped layer 162 can be an N-type doped silicon layer or a P-type doped silicon layer. The dielectric layer 163 is located above the doped layer 162 and can be a passivation antireflection layer. The multiple metal contacts 164 are arranged at intervals and pass through the dielectric layer 163 to be electrically connected to the doped layer 162. The conductive wire 150 is laid on the dielectric layer 163 and heated to bond the conductive wire 150 to the dielectric layer 163 and the multiple metal contacts 164, thus electrically connecting the conductive wire 150 to the multiple metal contacts 164.

[0082] The basic concepts have been described above. Obviously, for those skilled in the art, the above disclosure is merely illustrative and does not constitute a limitation of this application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this application. Such modifications, improvements, and corrections are suggested in this application, and therefore remain within the spirit and scope of the exemplary embodiments of this application.

[0083] Furthermore, this application uses specific terms to describe embodiments of the application. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic related to at least one embodiment of the application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0084] Similarly, it should be noted that, in order to simplify the description of the present application and thus aid in the understanding of one or more embodiments, the foregoing description of the embodiments of the present application sometimes combines multiple features into a single embodiment, drawing, or description thereof. However, this disclosure method does not imply that the subject matter of the present application requires more features than those mentioned in the claims. In fact, the embodiments contain fewer features than all the features of the single embodiments disclosed above.

[0085] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are modified in some examples with the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the characteristics required by individual embodiments. In some embodiments, numerical parameters should take into account specified significant digits and employ a general method of digit reservation. Although the numerical ranges and parameters used to confirm their breadth of scope in some embodiments of this application are approximate values, in specific embodiments, such values ​​are set as precisely as feasible.

[0086] Although this application has been described with reference to specific embodiments, those skilled in the art should recognize that the above embodiments are only used to illustrate this application, and various equivalent changes or substitutions can be made without departing from the spirit of this application. Therefore, any changes or modifications to the above embodiments within the essential spirit of this application will fall within the scope of the claims of this application.

Claims

1. A conductive wire production apparatus, characterized in that, include: A first channel has a first inlet and a first outlet, the first channel allowing a filamentous conductor to enter through the first inlet and exit through the first outlet; The second channel has a second inlet and a second outlet, the second outlet surrounding the first outlet. The second channel allows the coating material to enter through the second inlet and exit through the second outlet, and the coating material exiting through the second outlet covers the outer peripheral surface of the filamentous conductor.

2. The conductive wire production apparatus as described in claim 1, characterized in that, The second channel includes two independent sub-channels, the second feed inlet includes two independent sub-feed inlets, and the second discharge outlet includes two independent sub-discharge outlets. Each sub-channel is connected to the corresponding sub-feed inlet and sub-discharge outlet.

3. The conductive wire production apparatus as described in claim 2, characterized in that, The first discharge port is triangular, one of the two sub-discharge ports is adjacent to one side of the triangle, and the other of the two sub-discharge ports is adjacent to the other two sides of the triangle.

4. The conductive wire production apparatus as described in claim 1, characterized in that, The first discharge port is triangular, circular, elliptical, or trapezoidal.

5. The conductive wire production apparatus as described in claim 1, characterized in that, The coating material is a conductive paste or powdered metal particles. When the coating material is powdered metal particles, the conductive wire production device has the function of heating and melting the powdered metal particles.

6. The conductive wire production apparatus as described in claim 1, characterized in that, It also includes a first filamentary conductor feeding unit, which includes a crucible, a heating device, and a forming device. The crucible is used to hold the raw material for preparing the filamentary conductor, the heating device is used to heat the raw material, and the forming device is connected to the crucible. The forming device is used to cool the raw material and process the raw material into a filamentary conductor with a predetermined cross-section.

7. The conductive wire production apparatus as described in claim 1, characterized in that, It also includes a second filamentary conductor feed unit, which has a through hole with an inlet and an outlet, the cross-section of which gradually changes from the inlet to the outlet.

8. The conductive wire production apparatus as described in claim 1, characterized in that, It also includes a coating material feeding system, which is connected to the second feed port, wherein the coating material feeding system is used to provide the coating material to the second channel.

9. A method for preparing a solar cell, characterized in that, include: A filamentous conductor is supplied to the first channel through the first inlet, and the filamentous conductor is discharged from the first outlet of the first channel. A coating material is supplied to the second channel through the second inlet of the second channel. The second channel has a second outlet surrounding the first outlet, so that the coating material is discharged through the second outlet and covers the outer peripheral surface of the filamentous conductor to form a conductive wire including the filamentous conductor and the coating material covering the outer peripheral surface of the filamentous conductor. as well as The conductive wire is laid on the solar cell intermediate and heated to bond it to the solar cell intermediate, wherein the conductive wire is electrically connected to the solar cell intermediate.

10. The method for preparing a solar cell as described in claim 9, characterized in that, The second channel includes two independent sub-channels, the second feed port includes two independent sub-feed ports, and the second discharge port includes two independent sub-discharge ports. Each sub-channel is connected to the corresponding sub-feed port and sub-discharge port, and different covering materials are provided to the two sub-channels. The different covering materials cover a designated area on the outer periphery of the filamentous conductor.

11. The method for preparing a solar cell as described in claim 10, characterized in that, The cross-section of the filamentous conductor discharged through the first outlet is triangular, and different covering materials cover one side and the other two sides of the filamentous conductor respectively.

12. The method for preparing a solar cell as described in claim 9, characterized in that, The filamentary conductor is a metal wire comprising one or more of copper, silver, aluminum, and tin.

13. The method for preparing a solar cell as described in claim 9, characterized in that, The step of laying the conductive wire on the solar cell intermediate includes: laying the conductive wire on the solar cell intermediate through the first discharge port and the second discharge port.

14. The method for preparing a solar cell as described in claim 13, characterized in that, Methods for heating the conductive wire include: laser heating and drying heating.

15. The method for preparing a solar cell as described in claim 9, characterized in that, The step of laying the conductive wire on the solar cell intermediate includes: embedding at least a portion of the conductive wire into an adhesive film, and placing the adhesive film with the embedded conductive wire on the solar cell intermediate.

16. The method for preparing a solar cell as described in claim 15, characterized in that, The method for heating the conductive wire includes heating the conductive wire during the process of pressing the adhesive film using a hot pressing process.

17. The method for preparing a solar cell as described in claim 15, characterized in that, Also includes: Before placing the adhesive film with embedded conductive wires onto the solar cell intermediate, a layer of conductive paste is applied to the surface of the conductive wires that contact the solar cell intermediate, wherein the conductive wires are completely embedded in the adhesive film and the top surface of the conductive wires is lower than the top surface of the adhesive film.

18. The method for preparing a solar cell as described in claim 9, characterized in that, The step of laying the conductive wire on the solar cell intermediate includes: embedding the conductive wire into an adhesive film, applying a layer of conductive paste on the surface of the conductive wire in contact with the solar cell intermediate, and transferring the conductive wire onto the solar cell intermediate.

19. The method for preparing a solar cell as described in claim 9, characterized in that, The solar cell intermediate includes a transparent conductive layer. The conductive wire is laid on the transparent conductive layer and heated to bond the conductive wire to the transparent conductive layer. The conductive wire is electrically connected to the transparent conductive layer.

20. The method for preparing a solar cell as described in claim 9, characterized in that, The solar cell intermediate includes a doped layer, a dielectric layer, and multiple metal contacts. The dielectric layer is located above the doped layer, and the multiple metal contacts pass through the dielectric layer and are electrically connected to the doped layer. The conductive wire is laid on the dielectric layer and heated to bond the conductive wire to the dielectric layer and the multiple metal contacts, and the conductive wire is electrically connected to the multiple metal contacts.

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