Photovoltaic Laminate Metallization With Laser-Bonded Metal Foil
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Solution Overview
Problem
Current metallization techniques for solar cells in photovoltaic laminates require multiple steps, including physical deposition and soldering, which increase manufacturing costs and reduce output yield, necessitating a more efficient method for metal bonding and interconnect formation.
Innovation Solution
A single-step process involving a metal bond coupling a metal foil directly to a solar cell, using techniques such as laser bonding to form a metal contact region, which simplifies the metallization process and integrates metal interconnects into the photovoltaic laminate fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple-step metallization techniques (physical deposition and soldering) are used, then reliable metal bonding is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines multiple metallization steps (physical deposition and soldering) into a single integrated process. The metal foil is directly bonded to the solar cell contact regions through a unified metallization step, eliminating the need for separate deposition and soldering operations while maintaining bonding reliability.
Solution Approach 2:
The metal foil serves multiple functions simultaneously: it acts as both the electrical contact and the interconnect structure. This multi-functional approach replaces the need for separate metal layers and solder joints, simplifying the overall metallization process while ensuring reliable electrical connection.
2Reliability
If multiple-step metallization techniques are used, then metal interconnects are formed, but output yield decreases
Solution Approach 1:
By merging the metal foil bonding and interconnect formation into a single step, the patent eliminates multiple processing stages that could introduce defects or failures. This reduces the cumulative error rate and improves overall output yield while ensuring reliable metal interconnect formation.
3Ease of manufacture
If traditional metallization processes are used, then solar cells can be packaged, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate steps from the traditional metallization process. By directly bonding the metal foil to the solar cell contact regions without requiring separate deposition and soldering steps, the process is simplified while maintaining packaging capability, thereby reducing manufacturing 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
This approach reduces manufacturing complexity and costs, enhances output yield by streamlining the metallization process, and improves the efficiency of solar cell assembly into photovoltaic laminates.
Implementation Method 1
forming a metal bond can include firing a laser through the receiving medium to the metal foil to form a metal bond or a metal contact region that couples the metal foil to the first solar cell
Data Source
AI summary
A photovoltaic laminate is disclosed. Embodiments include placing a first encapsulant on a substantially transparent layer that includes a front side of a photovoltaic laminate. Embodiments also include placing a first solar cell on the first encapsulant. Embodiments include placing a metal foil on the first solar cell, where the metal foil uniformly contacts a back side of the first solar cell. Embodiments include forming a metal bond that couples the metal foil to the first solar cell. In some embodiments, forming the metal bond includes forming a metal contact region using a laser source, wherein the formed metal contact region electrically couples the metal foil to the first solar cell. Embodiments can also include placing a backing material on the metal foil. Embodiments can further include forming a back layer on the backing material layer and curing the substantially transparent layer, first encapsulant, first solar cell, metal foil, backing material and back layer to form a photovoltaic laminate.