Electroformed Free-Standing Metal Grid for Low-Shading Solar Cells
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Solution Overview
Problem
Current solar cell metallization methods, particularly those using silver or copper, are costly and inefficient, with silver being expensive and copper leading to contamination and manufacturing challenges, while alternative methods like wire grids and polymeric sheets face issues of high series resistance and alignment problems.
Innovation Solution
The development of a free-standing metallic article electroformed on a conductive mandrel with a preformed pattern, allowing for the creation of a metallic article with tailored aspect ratios and grid structures that minimize shading and series resistance, which can be easily aligned and integrated into solar cells, reducing material costs and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional semiconductor processing methods are used, then manufacturing complexity is reduced, but contamination control and particle management become problematic
Solution Approach 1:
The processing system is divided into multiple isolated reaction chambers (first reaction chamber, second reaction chamber) connected by transfer mechanisms. Each chamber can be independently controlled and maintained at different pressure levels, allowing contamination to be contained within specific zones while maintaining overall process integrity.
Solution Approach 2:
A transfer mechanism acts as an intermediary between reaction chambers, enabling controlled material transport while maintaining pressure differentials and preventing cross-contamination. The mechanism includes shielded transfer paths and controlled access points that mediate between different processing environments.
2Quantity of substance
If free-standing metallic articles are used instead of silicon wafers, then carrier substrate costs are reduced, but handling and processing difficulty increases
Solution Approach 1:
The free-standing metallic article is designed to be self-supported during processing, eliminating the need for traditional silicon wafer carriers. The article's own structural integrity allows it to be handled and processed without additional carrier substrates, reducing costs while maintaining ease of operation through simplified handling protocols.
3Reliability
If multiple processing steps are performed in separate chambers, then contamination is reduced, but processing time increases
Solution Approach 1:
Processing steps are performed in predetermined sequences within isolated chambers before final assembly. Critical processing operations are completed in advance in controlled environments, and intermediates are prepared beforehand in separate chambers, allowing for efficient batch processing that maintains particle control while optimizing cycle time.
Solution Approach 2:
The system enables continuous processing through coordinated operation of multiple chambers. While one chamber undergoes processing, another can simultaneously perform different operations, and transfer mechanisms operate continuously to move intermediates between chambers, maintaining uninterrupted productive action throughout the system.
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 reduced shading and series resistance, improving efficiency and cost-effectiveness by using a reusable mandrel for electroforming, allowing for high-throughput production of metallic articles that can be stably transferred and integrated into solar cells without affecting overall semiconductor assembly yields.
Implementation Method 1
a metallic article is electroformed on an electrically conductive mandrel
Data Source
Figure 1A~1B
Figure 2~3C
Figure 4~5
AI summary
A free-standing metallic article, and method of making, is disclosed in which the metallic article is electroformed on an electrically conductive mandrel. The mandrel has an outer surface with a preformed pattern, wherein at least a portion of the metallic article is formed in the preformed pattern. The metallic article is separated from the electrically conductive mandrel, which forms a free-standing metallic article that may be coupled with the surface of a semiconductor material for a photovoltaic cell.