Conformal Photovoltaic Stack on Grooved Substrate
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Solution Overview
Problem
Current solar panel technologies are expensive due to the need for complex processing techniques and high-cost materials, limiting the adoption of solar power as a clean energy alternative.
Innovation Solution
A photovoltaic device and method that employs a substrate with prefabricated grooves and a conformal photovoltaic stack comprising N-type, P-type, and intrinsic layers, which reduces processing costs and increases light absorption efficiency through mechanical grooving or embossing, eliminating the need for expensive lithographic patterning of nanorods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If nanorods are used to increase absorption length, then light absorption efficiency is improved, but manufacturing complexity and cost increase due to expensive patterning and etching steps
Solution Approach 1:
The substrate surface is segmented into periodic grooves and flat regions, creating a structured pattern that increases light absorption path length without requiring complex nanorod fabrication. This segmentation achieves the light-trapping effect of nanorods through simpler mechanical grooving
Solution Approach 2:
The patent replaces complex chemical etching and lithographic patterning processes with mechanical grooving or embossing to create the light-trapping structure. This substitution dramatically simplifies the manufacturing process while maintaining the optical benefits of structured surfaces
2Reliability
If integrated circuit technology is incorporated into solar cell fabrication, then device performance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent employs inexpensive mechanical grooving tools and simple substrate materials instead of expensive integrated circuit fabrication equipment and processes. The focus is on creating functional structures through low-cost mechanical means rather than high-precision semiconductor manufacturing
Solution Approach 2:
The patent changes the fabrication approach from precision lithographic patterning to mechanical grooving with relaxed dimensional tolerances. This parameter change in the manufacturing process significantly reduces equipment requirements and production costs while maintaining effective light absorption
3Ease of manufacture
If conventional planar solar cell structure is used, then manufacturing is simple, but light absorption efficiency is limited
Solution Approach 1:
The patent transitions from a two-dimensional planar surface to a three-dimensional structured surface with periodic grooves. This dimensional change increases the effective light absorption path length and surface area while maintaining compatibility with simple manufacturing processes
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 higher absorption efficiency and reduced light degradation, achieving enhanced current density and voltage performance while lowering production costs, making solar energy more viable.
Implementation Method 1
The photovoltaic stack has a thickness of less than one micron and is configured to transduce incident radiation into current flow
Data Source
AI summary
A photovoltaic device and method include a substrate layer having a plurality of structures including peaks and troughs formed therein. A continuous photovoltaic stack is conformally formed over the substrate layer and extends over the peaks and troughs. The photovoltaic stack has a thickness of less than one micron and is configured to transduce incident radiation into current flow.