Heterojunction Battery Metal Mesh Electrodes for Lower Silver Use
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Solution Overview
Problem
Conventional heterojunction batteries face high production costs due to excessive silver paste consumption, the rarity of indium tin oxide, and the need for specialized low-temperature equipment, which increases the cost of manufacturing.
Innovation Solution
The heterojunction battery design incorporates metal meshes composed of multiple metal wires, eliminating the need for expensive resin-type low-temperature solidified silver paste and allowing for series connection without soldering, thus reducing production costs and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin-type low temperature solidified silver paste is used to prepare electrode, then electrical conductivity of electrode is improved, but silver paste consumption increases and production cost increases
Solution Approach 1:
The patent extracts and removes the resin binder component from the silver paste, creating a binder-free silver paste. This eliminates the need for resin-type low temperature solidified paste while maintaining electrical conductivity through the metal mesh structure alone, thereby reducing silver paste consumption without compromising electrode performance
Solution Approach 2:
The patent employs a metal mesh structure that can be directly applied and functions immediately without requiring complex resin-based paste applications. This simplified approach replaces expensive resin-type paste with a more economical metal mesh solution that achieves the same electrical conductivity function with less material
2Reliability
If width of metal electrode or height of metal electrode is increased to improve electrical conductivity, then electrical conductivity of electrode is improved, but silver paste consumption increases
Solution Approach 1:
The patent transitions from increasing the width or height (2D dimensions) of metal electrodes to creating a three-dimensional metal mesh structure. This mesh structure provides multiple conductive pathways through its spatial configuration, achieving superior electrical conductivity without increasing the amount of silver paste consumed, as the conductivity is enhanced through structural geometry rather than material quantity
3Ease of manufacture
If low temperature solder strip and low temperature series welding machine are used for heterojunction battery assembly, then assembly is feasible at low temperature, but equipment cost increases
Solution Approach 1:
The patent employs standard solder strips and standard series welding machines that can be used across multiple battery types and applications, not just heterojunction batteries. This universal equipment approach eliminates the need for specialized low-temperature equipment, reducing equipment costs while still achieving feasible assembly through the robust metal mesh structure that tolerates standard welding temperatures
Solution Approach 2:
The metal mesh structure inherently provides its own mechanical strength and electrical conductivity functions, eliminating the need for additional low-temperature specialized equipment to facilitate assembly. The structure serves multiple functions simultaneously, allowing standard equipment to be used without requiring temperature-modified tools
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 design significantly decreases production costs by minimizing silver paste usage and eliminating the need for specialized equipment, while maintaining conversion efficiency and simplifying the assembly process.
Implementation Method 1
The first metal mesh penetrates through the first dielectric film and is fixedly connected to the first transparent conductive oxide layer. The second metal mesh penetrates through the second dielectric film and is fixedly connected to the second transparent conductive oxide layer.
Implementation Method 2
a first transparent conductive oxide layer... a second transparent conductive oxide layer
Data Source
AI summary
A heterojunction battery, a preparation method therefor, and an application thereof are provided. The heterojunction battery includes a substrate, a first intrinsic amorphous silicon layer, an N-type doped amorphous silicon layer or microcrystalline silicon layer or nanocrystalline silicon layer, a first transparent conductive oxide layer, a second intrinsic amorphous silicon layer, a P-type doped amorphous silicon layer or microcrystalline silicon layer or nanocrystalline silicon layer, a second transparent conductive oxide layer, and a dielectric film. The heterojunction battery further includes a metal mesh. The metal mesh penetrates through the dielectric film and is fixedly connected to the first transparent conductive oxide layer and the second transparent conductive oxide layer, respectively. The metal mesh is composed of multiple first metal wires and multiple second metal wires. The first metal wires are perpendicular to the second metal wires.