Aperture-Based Optoelectronic Device for Solar Cell Manufacturing
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Solution Overview
Problem
Existing solar photovoltaic cells are expensive, inefficient, and fragile, making them challenging to produce surfaces suitable for electrical conductor and semiconductor material application.
Innovation Solution
An optoelectronic device with a substrate featuring a series of apertures and channels, where the apertures are coated with semiconductor materials and conductor materials, allowing for efficient electrical communication and separation, thereby reducing production costs and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional solar photovoltaic cell surfaces are used, then electrical conductor and semiconductor materials can be applied, but the production cost is high and the surface is difficult and expensive to produce
Solution Approach 1:
The substrate surface is segmented into multiple apertures arranged in series, creating discrete regions that guide material deposition. This segmentation allows standard materials to be applied in a controlled manner through the aperture structures, reducing the need for complex surface preparation while maintaining manufacturing precision.
Solution Approach 2:
The aperture structure acts as an intermediary between the substrate and the electrical conductor/semiconductor materials. This intermediary structure simplifies the surface geometry, making it easier to apply materials uniformly while the aperture configuration ensures proper electrical isolation and connection.
2Reliability
If existing solar photovoltaic cell structures are used, then electrical functionality is achieved, but the device is fragile and easily damaged
Solution Approach 1:
The device is segmented into modular units with apertures that can be independently formed and filled. This segmentation allows each region to be optimized for its specific function while the overall structure gains resilience through distributed architecture, reducing the impact of localized damage.
Solution Approach 2:
The substrate is designed with inherent structural features (apertures and thickness) that provide mechanical strength before operational stresses are applied. The aperture configuration and substrate geometry are optimized to distribute mechanical loads, preventing crack propagation and enhancing durability against environmental stresses.
3Ease of manufacture
If existing solar photovoltaic cell surfaces are used, then electrical conduction is achieved, but production costs are high
Solution Approach 1:
The aperture structure serves multiple functions simultaneously: it guides material deposition, provides electrical isolation between adjacent regions, enables light penetration to the active layers, and maintains mechanical integrity. This multi-functionality eliminates the need for separate specialized components, reducing production costs while maintaining electrical efficiency.
Solution Approach 2:
The aperture configuration enables self-alignment and self-isolation during material deposition. The geometric arrangement of apertures automatically provides electrical isolation between adjacent conductive regions without requiring additional insulating materials or complex processing steps, reducing manufacturing complexity and cost.
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
The solution results in a cost-effective and robust solar photovoltaic cell with improved durability, enabling easier installation and a broader range of applications, while maintaining electrical efficiency.
Implementation Method 1
The interface between the first semiconductor material and the second semiconductor material forms a p-n junction. The p-n junction can be thought of as the active site where the generation or consumption of electrical energy occurs.
Implementation Method 2
The term photovoltaic refers to the production of electricity, normally direct electrical current, from light at the junction between two materials that are exposed to the light.
Data Source
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AI summary
An optoelectronic device and method of producing the same. The optoelectronic device comprising a substrate having a first and a second substantially planar face and an aperture therein, the aperture passing through and penetrating the first and second substantially planar faces of the substrate. The aperture has a first and a second face defining a space therebetween. The space is at least partially filled with a first semiconductor material, the first face is coated with a conductor material and the second face is coated with a second semiconductor material.