IBC Solar Cell Emitter Layout With Tunneling Layer Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing interdigitated back-contact (IBC) solar cells face challenges in enhancing electrical performance and reducing preparation costs, particularly in achieving optimal electrode alignment and minimizing carrier recombination and short-circuit issues.

Innovation Solution

The design includes a solar cell with distinct regions having different conductivity type emitters, where the second emitter is thinner and has a specific thickness to control carrier resistance, and a tunneling layer with different dielectric materials to isolate emitters and reduce alignment complexity, allowing for single patterning processes and improved electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple patterning processes are used to form electrodes with different conductivity types, then electrode precision and electrical performance are improved, but manufacturing complexity and preparation cost increase

Engineering Contradiction:

Improveelectrode positioning precisionVSAvoidpatterning process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The solar cell structure is divided into first and second regions with different conductivity types (P-type and N-type), allowing each region to be optimized independently while using a unified patterning approach for electrode formation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a single patterning process that forms electrodes of different conductivity types by controlling doping parameters and material deposition conditions during the manufacturing process, eliminating the need for multiple separate patterning steps

Inventive Principle:

Principle #35Parameter changes

2Reliability

If electrode thickness is increased to reduce resistance, then electrical conductivity is improved, but carrier recombination increases and photoelectric conversion efficiency decreases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidcarrier recombination loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent optimizes the thickness parameter of the tunneling layer and emitter layers to achieve the optimal balance between electrical conductivity and carrier recombination prevention, using specific thickness ranges (e.g., 30-200 nm for certain layers) to simultaneously satisfy both requirements

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The solar cell structure incorporates multiple layers with different material compositions and conductivity types (P-type and N-type emitters, tunneling layers, dielectric layers) to achieve both low resistance and reduced carrier recombination through material property optimization

Inventive Principle:

Principle #40Composite materials

3Reliability

If alignment precision between electrodes is increased to avoid short-circuits, then electrical performance is improved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improveshort-circuit preventionVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The solar cell is segmented into distinct first and second regions with different conductivity types, where each region's electrodes are formed through coordinated patterning processes that inherently maintain proper spacing and alignment, preventing short-circuits through structural design rather than relying solely on high-precision alignment

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Dielectric layers and tunneling layers serve as intermediary structures between the P-type and N-type electrodes, providing physical separation and electrical isolation that prevents short-circuits while allowing for less stringent alignment requirements during manufacturing

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration enhances electrical performance by reducing carrier recombination and short-circuit currents, while simplifying the manufacturing process and reducing costs by minimizing the need for precise alignment and multiple masks.

Implementation Method 1

a tunneling layer covering the second surface

Methodology Applied

Scientific EffectQuantum tunneling:

Implementation Method 2

A solar cell is a photovoltaic device for converting solar radiation energy to electric energy

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS20240170588A1Solar cell and solar cell module

Publication Date: 2024.05.23 JINKO SOLAR CO LTD

AI summary

Embodiments of the present disclosure provide a solar cell and a solar cell module. The solar cell includes a first region and a second region, and further includes a substrate having a first surface and a second surface; a tunneling layer covering the second surface; a first emitter formed on part of the tunneling layer in the first region; and a second emitter formed on part of the tunneling layer in the second region and on the first emitter, a conductivity type of the second emitter being different from a conductivity type of the first emitter. The solar cell further includes a first electrode configured to electrically connect with the first emitter by penetrating through the second emitter; and a second electrode formed in the second region and configured to electrically connect with the second emitter.