CdTe PV Module Integrated Treatment System
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Solution Overview
Problem
The introduction of impurities and atmospheric variables during the manufacturing of cadmium telluride (CdTe) photovoltaic modules due to exposure to room atmosphere between cadmium chloride treatment and annealing processes leads to inconsistent module production in large-scale manufacturing.
Innovation Solution
An integrated treatment system with a preheat section, treatment chamber, and anneal oven, where substrates are continuously conveyed through a controlled environment, allowing for precise temperature control and application of cadmium chloride as a liquid treatment composition, followed by annealing at elevated temperatures to dope the cadmium telluride layer, thereby minimizing exposure to impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cadmium chloride treatment and annealing are performed as separate processes with room atmosphere exposure in between, then the manufacturing process is simpler and more flexible, but impurities are introduced and manufacturing precision deteriorates
Solution Approach 1:
The patent combines the cadmium chloride treatment and annealing processes into a single integrated process by providing the cadmium chloride solution to the substrate while it is in the annealing oven, eliminating the need for separate transport steps and preventing atmospheric contamination between steps
Solution Approach 2:
The annealing oven serves as an intermediary controlled environment that protects the substrate from room atmosphere exposure during the treatment process, allowing both cadmium chloride application and annealing to occur in a consistent, impurity-free environment
2Device complexity
If the substrate is transported between treatment and annealing in room atmosphere, then the equipment setup is simpler, but manufacturing precision and reliability deteriorate due to impurity introduction
Solution Approach 1:
The patent merges the treatment and annealing operations into a single equipment system, where the cadmium chloride solution is delivered to the substrate within the annealing oven, eliminating intermediate transport and ensuring consistent process conditions
Solution Approach 2:
The annealing oven provides a controlled, inert atmosphere environment that prevents atmospheric contaminants from contacting the substrate during the critical treatment and annealing processes, thereby improving process reliability
3Ease of operation
If room atmosphere exposure is allowed between treatment steps, then the manufacturing process is more flexible and easier to operate, but manufacturing precision and uniformity deteriorate
Solution Approach 1:
The annealing oven acts as an intermediary controlled environment that maintains consistent conditions during both cadmium chloride treatment and annealing, preventing atmospheric variables from affecting treatment uniformity while preserving operational simplicity
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 enhances the consistency and efficiency of cadmium telluride thin film photovoltaic device manufacturing by reducing impurity introduction and ensuring uniform treatment, resulting in improved performance and reliability of CdTe PV modules.
Implementation Method 1
a preheat section, a treatment chamber, and an anneal oven that are integrally interconnected within the treatment system. The conveyor system is operably disposed within the treatment system and configured for transporting substrates in a serial arrangement into and through the preheat section
Implementation Method 2
the anneal oven is configured to heat the substrates with the cadmium telluride thin film thereon to an annealing temperature of from about 250° C. to about 500° C. as the substrates are continuously conveyed by the conveyer system through the treatment system, such that the cadmium telluride thin film on the substrates is doped with a material from the liquid treatment composition
Implementation Method 3
CdTe has an energy bandgap of about 1.45 eV, which enables it to convert more energy from the solar spectrum as compared to lower bandgap semiconductor materials historically used in solar cell applications. Free carrier pairs are created by light energy and then separated by the p-n heterojunction to produce an electrical current
Data Source
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AI summary
Systems and processes for treatment of a cadmium telluride thin film photovoltaic device 10 are generally provided. The systems can include a treatment system 100 and a conveyor system 110. The treatment system 100 includes a preheating section 102, a treatment chamber 104, and an anneal oven 106 that are integrally interconnected within the treatment system 100. The conveyor system 110 is operably disposed within the treatment system 100 and configured for transporting substrates 12 in a serial arrangement into and through the preheat section 102, into and through the treatment chamber 104, and into and through the anneal oven 106 at a controlled speed. The treatment chamber 104 is configured for applying a material to a thin film on a surface of the substrate 12 and the anneal oven 106 is configured to heat the substrate 12 to an annealing temperature as the substrates 12 are continuously conveyed by the conveyor system 110 through the treatment chamber 104.