Microcrystalline Silicon Solar Cell in Active Array Switch Substrate
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Solution Overview
Problem
Current solar cells, particularly those using monocrystalline and polycrystalline silicon, face high production costs and low optical-to-electrical conversion efficiency due to their inability to absorb the entire solar spectrum, with amorphous silicon thin films only effectively converting light with wavelengths less than 750 nm.
Innovation Solution
The implementation of a substrate with active array switches featuring a microcrystalline silicon structure, including a P-I-N layer stack for solar cells, where the I-type layer is manufactured via plasma-enhanced chemical vapor deposition using silane and hydrogen, and a transparent electrode made from materials like zinc oxide, indium tin oxide, to enhance optical-to-electrical conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If amorphous silicon thin film is used in optical-to-electrical conversion layer, then manufacturing cost is reduced and ease of manufacture is improved, but optical-to-electrical conversion efficiency deteriorates due to inability to absorb entire solar spectrum
Solution Approach 1:
The patent segments the optical-to-electrical conversion function into multiple layers with different bandgaps. The first conversion layer uses amorphous silicon with bandgap 1.75-1.8 eV to absorb high-energy photons (wavelength < 750 nm), while the second conversion layer uses microcrystalline silicon with bandgap 1.1-1.2 eV to absorb lower-energy photons (wavelength 750-1100 nm). This segmentation allows each layer to specialize in absorbing specific wavelength ranges, collectively covering a broader solar spectrum and improving overall conversion efficiency while maintaining the manufacturing advantages of thin film technology.
Solution Approach 2:
The patent employs composite material structure by combining amorphous silicon and microcrystalline silicon in a tandem configuration. Each material has distinct optical and electrical properties suited for different portions of the solar spectrum. The amorphous silicon layer provides good light absorption and ease of fabrication, while the microcrystalline silicon layer complements it by absorbing longer wavelengths. This composite approach leverages the strengths of both materials to achieve superior overall performance.
2Loss of energy
If monocrystalline silicon and polycrystalline silicon are used in solar cells, then optical-to-electrical conversion efficiency is improved, but manufacturing cost increases and productivity decreases due to high material consumption
Solution Approach 1:
The patent adopts thin film solar cell technology using amorphous silicon and microcrystalline silicon deposited in thin layers (typically micrometer scale) on substrate surfaces. This thin film approach dramatically reduces material consumption compared to bulk monocrystalline or polycrystalline silicon wafers, enabling large-area production and improving productivity. The thin films can be deposited using plasma-enhanced chemical vapor deposition (PECVD) or other low-cost techniques, facilitating massive production while maintaining competitive conversion efficiency through the tandem layer structure.
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 allows for improved solar energy generation efficiency by absorbing a broader range of wavelengths, including longer wavelengths, thereby increasing the overall energy conversion efficiency of solar cells.
Implementation Method 1
According to the photo-electric effect, when a ray of light is irradiated onto a conductor or a semiconductor, photons act with electrons in the conductor or the semiconductor, causing the electrons to flow
Implementation Method 2
the I-type layer of the microcrystalline silicon structure is manufactured by performing plasma enhanced chemical vapor deposition (PECVD) on silane (SiH4) and hydrogen (H2)
Data Source
AI summary
This application provides a display device and an active array switch substrate thereof. The active array switch substrate includes: a substrate; active array switches, formed on the substrate, where the active array switch includes a source electrode; at least one solar structure, disposed on the source electrode, where the solar structure includes a solar cell; and a transparent electrode, covered on the solar cell. The solar cell includes an N-type layer, an I-type layer of a microcrystalline silicon structure, and a P-type layer sequentially stacked in a direction away from the source electrode.