Heterojunction Solar Cell Light Sintering

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Solution Overview

Problem

Current solar cell manufacturing processes, particularly for heterojunction solar cells, face challenges in maximizing efficiency and minimizing costs, especially in forming electrode patterns using high-temperature sintering methods which can deteriorate film properties and are time-consuming.

Innovation Solution

A method involving light sintering using a xenon flash lamp to form metal compound, transparent conductive oxide, and electrode layers simultaneously, reducing processing time and cost, and preventing film deterioration, with specific parameters such as energy, pulse width, and pulse number optimized for efficient sintering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-temperature sintering method is used to form electrode pattern, then electrode conductivity is improved, but film properties deteriorate and manufacturing time increases

Engineering Contradiction:

Improveelectrode conductivityVSAvoidfilm properties

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces thermal sintering with light sintering using a xenon flash lamp. Instead of using high-temperature thermal fields to sinter the electrode paste, the invention uses intense pulsed light irradiation to rapidly heat and sinter the electrode material. This substitution of the sintering mechanism resolves the contradiction by achieving electrode conductivity improvement without the detrimental effects of prolonged high-temperature thermal processing on film properties

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs pulsed light irradiation with specific pulse width (0.1ms to 50ms) and pulse number (1 to 100 times) to sinter the electrode. This periodic action allows controlled energy delivery that achieves sufficient sintering while minimizing thermal damage to underlying films, thus improving electrode conductivity without deteriorating film properties

Inventive Principle:

Principle #19Periodic action

2Reliability

If high-temperature sintering method is used to form electrode pattern, then electrode conductivity is improved, but manufacturing time increases

Engineering Contradiction:

Improveelectrode conductivityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses intense pulsed light irradiation to rapidly sinter the electrode in a very short time (0.1ms to 50ms per pulse). This rushing through the sintering process achieves the necessary electrode conductivity without the prolonged exposure times required by conventional thermal sintering, thus resolving the time loss issue

Inventive Principle:

Principle #21Skipping (Rushing through)

3Manufacturing precision

If multiple separate sintering processes are used to form metal compound, transparent conductive oxide, and electrode layers, then each layer can be optimized, but manufacturing complexity and time increase

Engineering Contradiction:

Improvelayer optimizationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the sintering of metal compound layer, transparent conductive oxide layer, and electrode pattern into a single light sintering process. By using a xenon flash lamp with appropriate energy and pulse parameters, all three layers are simultaneously sintered in one step, achieving manufacturing efficiency improvement while maintaining layer optimization through pre-formed layer structures that are activated together

Inventive Principle:

Principle #5Merging (Combining)

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 efficiency and reduces the manufacturing cost of heterojunction solar cells by minimizing thermal processing effects, improving film properties, and shortening the production time, thereby improving the productivity and efficiency of the solar cells.

Implementation Method 1

sintering the electrode forming material using light sintering to form an electrode part. The transparent conductive oxide may be sintered by light sintering to form a transparent conductive oxide layer formed of the transparent conductive oxide.

Methodology Applied

Scientific EffectLight sintering: Sintering

Implementation Method 2

light sintering can be performed using a xenon flash lamp having an energy (E) of 5 J/cm2 to 500 J/cm2, a pulse width (W) of 0.1 ms to 50 ms, a pulse number (N) of 1 to 100 times, and a pulse gap of 1 ms to 100 ms.

Methodology Applied

Scientific EffectPhotothermal heating: Heating

Data Source

PatentUS10249776B2Heterojunction solar cell and manufacturing method thereof

Publication Date: 2019.04.02 TRINA SOLAR CO LTD

AI summary

Discussed is a method of manufacturing a heterojunction solar cell, including: forming a metal compound on a semiconductor substrate; forming a transparent conductive oxide on the metal compound; forming an electrode forming material on the transparent conductive oxide; and sintering the electrode forming material using light sintering to form an electrode part. The transparent conductive oxide may be sintered by light sintering to form a transparent conductive oxide layer formed of the transparent conductive oxide.