Printed Solar Battery Electrode Structure Without Plating or Sputtering
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Solution Overview
Problem
Existing solar battery manufacturing processes are complicated, costly, and prone to defects due to the use of plating and sputtering methods, leading to poor contact properties and increased manufacturing costs.
Innovation Solution
A solar battery with an electrode structure that includes a metal and adhesive material in a conductive region, utilizing a polycrystalline semiconductor layer, and a single printed layer formed by a low-temperature electrode paste, which simplifies the manufacturing process and improves electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plating is used to form the electrode, then contact properties are improved, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent extracts and eliminates the plating process from the manufacturing sequence, replacing it with a direct screen printing method that forms the electrode pattern in a single step without requiring separate seed layer formation and plating operations
Solution Approach 2:
The patent combines the electrode formation process with the screen printing process, integrating multiple functions (pattern formation, material deposition, and contact creation) into a single manufacturing step, thereby reducing process complexity while maintaining contact properties
2Manufacturing precision
If sputtering process is used to form the electrode, then electrode thickness is controlled, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent removes the sputtering process entirely from the manufacturing sequence, replacing it with screen printing that achieves the desired electrode thickness through controlled paste formulation and printing parameters, eliminating the need for vacuum equipment and complex process control
Solution Approach 2:
The patent employs a consumable screen printing paste that is applied directly and fired to form the electrode, replacing expensive and time-consuming sputtering processes with a simpler, more cost-effective printing approach that achieves sufficient electrode properties
3Reliability
If multiple layers are stacked to improve resistivity characteristics, then electrical characteristics are improved, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent combines multiple functional components (conductive material, adhesive material, and filler particles) into a single multi-functional screen printing paste formulation, achieving the desired resistivity characteristics without requiring separate metal layer stacking operations
Solution Approach 2:
The patent employs a composite paste material containing conductive particles, adhesive binders, and filler materials in specific ratios, creating a single-layer electrode structure that achieves the required electrical properties through material composition rather than multi-layer stacking
4Manufacturing precision
If wet etching process is used to form the electrode, then electrode pattern is created, but damage to solar battery occurs and process complexity increases
Solution Approach 1:
Instead of forming a complete electrode layer and then removing unwanted portions through etching, the patent inverts the approach by using the screen printing mask to prevent material deposition only where the electrode should not be formed, thereby creating the pattern directly without harmful chemical etching steps
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 improved electrode structure enhances resistance and contact properties, reduces process complexity, and increases productivity and reliability of solar batteries and panels by minimizing defects and simplifying the manufacturing process.
Implementation Method 1
a first metal that reacts with a semiconductor material included in the polycrystalline semiconductor layer to form a compound layer including a metal-semiconductor compound
Data Source
AI summary
A solar battery according to the present embodiment has an electrode, which includes a metal and an adhesive material, formed in a conductive region including a polycrystalline semiconductor layer, and thus, the electrical characteristics of the solar battery may be improved and the manufacturing process thereof may be simplified. More specifically, the solar battery includes a semiconductor substrate, and the conductive region including the polycrystalline semiconductor layer is positioned on one surface of the semiconductor substrate.