3D Solar Cell Structure for Increased Power Generation Area
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Solution Overview
Problem
Current solar cell technologies require a large installation area to achieve significant power generation, limiting efficiency and increasing costs, despite advancements in photovoltaic power generation.
Innovation Solution
A method of manufacturing solar cells with an increased power generation area by forming protrusions on a flexible substrate, allowing for the sequential deposition of layers using a rolling process and annealing equipment, which enhances the contact area between layers and improves power production without increasing the cell size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If conventional flat solar cell structure is used, then manufacturing process is simple, but power generation area is limited
Solution Approach 1:
The invention transitions from a two-dimensional flat substrate to a three-dimensional structure by forming protrusions that extend upward from the substrate surface. This dimensional change allows multiple layers to be stacked vertically on the same footprint area, thereby increasing the power generation area without expanding the horizontal installation space.
Solution Approach 2:
The invention implements a multi-layer nested structure where multiple solar cell layers are stacked vertically one on top of another on the same substrate area. Each layer contains solar cells that generate power, and the nested arrangement allows maximum utilization of the substrate area, effectively multiplying the power generation capacity within the same installation footprint.
2Productivity
If multi-layer structure is formed to increase power generation area, then power generation capacity increases, but manufacturing precision requirements increase
Solution Approach 1:
The substrate is pre-formed with protrusions before the solar cell layers are deposited. This preliminary structuring creates predetermined positioning features that guide the sequential formation of multiple layers, ensuring that each layer is deposited at the correct location and orientation, thereby maintaining manufacturing precision throughout the multi-layer fabrication process.
Solution Approach 2:
The manufacturing process is divided into discrete sequential steps: substrate preparation with protrusions, followed by sequential deposition of individual layers. Each layer is formed independently in a controlled manner, allowing precise control over layer thickness, composition, and positioning, which maintains manufacturing precision while enabling high power generation capacity.
3Productivity
If substrate is wound in roll form for continuous production, then manufacturing efficiency increases, but substrate handling complexity increases
Solution Approach 1:
The substrate is designed to be flexible and is handled in a dynamic roll-to-roll format during manufacturing. The substrate can be continuously fed through the production line, wound into rolls for storage or transport, and unwound as needed. This dynamic handling approach enables continuous high-volume production while the flexible substrate material accommodates the winding and unwinding operations without damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of solar cells with enhanced power generation capabilities, reducing unit costs and expanding the usability of solar power generation to areas previously unsuitable for conventional panels.
Implementation Method 1
In the protrusion forming step, the protrusion is formed by pressing the substrate
Implementation Method 2
a drum disposed inside a firing furnace and mounted thereon with the substrate to heat the mounted substrate during transfer
Implementation Method 3
a drum disposed inside a firing furnace and mounted thereon with the substrate to heat the mounted substrate during transfer
Implementation Method 4
a target spaced apart from an outer circumference of the drum, and having a material for forming any one of the layers
Implementation Method 5
In the step of forming the layers, post-processing is performed by an annealing equipment on the substrate on which the one of the layers is formed
Data Source
AI summary
Discloses is a method of manufacturing a solar cell with an increased power generation area to increase the area used for actual power generation without increasing the size of the solar cell.