Multilayer Front Electrode for Photovoltaic Devices
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Solution Overview
Problem
Conventional photovoltaic devices with single-layer transparent conductive oxide (TCO) front electrodes suffer from high sheet resistance, significant infrared radiation transmission leading to increased operating temperature, reduced light transmission, high fabrication costs, and a narrow process window, which limits their efficiency and output power.
Innovation Solution
A multilayer front electrode with a patterned transparent conductive coating (TCC) comprising metallic IR reflecting layers and TCO layers, applied on a textured glass substrate, reduces sheet resistance, enhances infrared reflection, increases visible light transmission, and expands the process window, thereby improving photovoltaic module output power and reducing fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer transparent conductive oxide (TCO) is used as the front electrode, then the fabrication process is simple, but the sheet resistance is high which reduces photovoltaic module output power
Solution Approach 1:
The patent applies composite materials by combining multiple layers including TCO layers, metallic IR reflecting layers, and dielectric layers to create a multilayer front electrode. This composite structure achieves low sheet resistance (improving power output) while maintaining fabrication feasibility through established coating processes
2Device complexity
If a single-layer TCO front electrode is used, then the structure is simple, but infrared radiation transmission is significant leading to increased operating temperature
Solution Approach 1:
The patent incorporates metallic IR reflecting layers within the multilayer TCC structure to specifically reflect infrared radiation. This composite approach selectively addresses the thermal issue without requiring complete structural redesign, maintaining reasonable complexity while achieving temperature reduction
Solution Approach 2:
The patent applies local quality by giving different layers specific functions: TCO layers for conductivity and visible light transmission, metallic layers for IR reflection, and dielectric layers for optical optimization. Each layer is optimized for its specific role, allowing the electrode to simultaneously manage different aspects of light and heat
3Power
If a thicker TCO layer is used to reduce sheet resistance, then conductivity improves, but light transmission in the visible spectrum decreases
Solution Approach 1:
The patent segments the electrode function into multiple thin layers rather than using one thick TCO layer. The multilayer structure includes alternating TCO, metallic IR reflecting, and dielectric layers, where each layer is optimized for specific functions. This segmentation allows achieving low sheet resistance through the composite structure while maintaining high visible light transmission
Solution Approach 2:
The patent uses composite materials to replace the function of a thick TCO layer. The combination of thin TCO layers with metallic IR reflecting layers and dielectric layers creates a composite structure that provides both electrical conductivity and optical transparency, overcoming the trade-off inherent in single-layer designs
4Ease of manufacture
If conventional single-layer TCO electrodes are used, then fabrication costs are high, but the process window is narrow limiting manufacturing flexibility
Solution Approach 1:
The patent employs composite materials in the multilayer TCC structure to achieve both cost reduction and improved process window. The use of alternative materials such as sputtered metal oxides and organic-inorganic hybrid perovskites provides manufacturing flexibility while the multilayer composite design allows optimization of each layer's properties to reduce overall fabrication costs
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
The multilayer front electrode design achieves reduced sheet resistance, increased infrared reflection, enhanced light transmission in the visible spectrum, and a broader process window, leading to improved photovoltaic module efficiency and cost-effectiveness.
Implementation Method 1
The patterned first surface of the glass substrate reduces reflection loss of incident solar flux and increases the absorption of photon(s) in the semiconductor film through scattering, refraction and diffusion
Implementation Method 2
The patterned first surface of the glass substrate reduces reflection loss of incident solar flux and increases the absorption of photon(s) in the semiconductor film through scattering, refraction and diffusion
Implementation Method 3
The TCC may act to enhance transmission in selected PV active regions of the visible and near IR spectrum, while substantially rejecting and/or blocking undesired IR thermal energy from certain other areas of the spectrum
Implementation Method 4
The multilayer front electrode coating is designed to realize increased reflection of infrared (IR) radiation thereby reducing the operating temperature of the photovoltaic module
Data Source
AI summary
This invention relates to a front electrode/contact for use in an electronic device such as a photovoltaic device. In certain example embodiments, the front electrode of a photovoltaic device or the like includes a multilayer coating including at least one transparent conductive oxide (TCO) layer (e.g., of or including a material such as tin oxide, ITO, zinc oxide, or the like) and/or at least one conductive substantially metallic IR reflecting layer (e.g., based on silver, gold, or the like). In certain example instances, the multilayer front electrode coating may include one or more conductive metal(s) oxide layer(s) and one or more conductive substantially metallic IR reflecting layer(s) in order to provide for reduced visible light reflection, increased conductivity, cheaper manufacturability, and/or increased infrared (IR) reflection capability. At least one of the surfaces of the front glass substrate may be textured in certain example embodiments of this invention.