Silicon Substrate Gettering and Single-Side Texturing for HJT Solar Cells
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Solution Overview
Problem
The existing manufacturing processes for silicon-based heterojunction solar cells require improvements in gettering steps and preparation processes to enhance the performance and efficiency of silicon substrates, particularly in terms of surface passivation and filling factor.
Innovation Solution
A manufacturing method involving double-side polishing of a silicon substrate, followed by gettering treatment to form doped and glass layers, then single-side texturing and rounding, followed by the formation of intrinsic and doped silicon-containing layers and transparent conductive layers, with specific materials and thicknesses used to optimize the substrate surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gettering process is used, then battery efficiency can be improved, but the manufacturing process complexity increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple separate process steps (texturing, gettering, and surface treatment) into a single integrated process by adding glass layers during the texturing step that serve dual purposes: as texturing agents and as gettering sources. This merging eliminates the need for separate gettering process steps, thereby reducing manufacturing complexity while maintaining battery efficiency.
Solution Approach 2:
The glass layers formed during texturing serve multiple functions simultaneously: they act as texturing agents to create light-trapping surfaces, as gettering sources to remove impurities from the silicon substrate, and as protective layers during subsequent processing. This multi-functionality reduces the number of separate process steps needed, improving production efficiency without compromising battery performance.
2Reliability
If multiple separate process steps are used for texturing and gettering, then treatment effectiveness is improved, but chemical consumption and manufacturing cost increase
Solution Approach 1:
The patent merges the texturing and gettering processes into a single step by incorporating gettering source material (glass layers) into the texturing process. This eliminates the need for separate chemical treatments for each function, thereby reducing overall chemical consumption while maintaining effective treatment of the silicon substrate surface.
Solution Approach 2:
The glass layers perform multiple functions simultaneously - serving as both texturing agents and gettering sources. This multi-functionality means that a single material addition achieves what would traditionally require multiple separate chemical treatments, reducing chemical consumption and manufacturing cost while preserving treatment effectiveness.
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 method improves the passivation performance, increases light utilization, and enhances battery efficiency by reducing the weight and chemical consumption, while simplifying the manufacturing process and saving costs.
Implementation Method 1
performing a gettering treatment on the silicon substrate, including: placing the silicon substrate in a gettering source to form a first silicon doped layer and a first silicon glass layer on a first surface of the silicon substrate
Implementation Method 2
texturing the first surface of the silicon substrate, removing the first silicon doped layer, and simultaneously forming a textured surface on the first surface of the silicon substrate
Data Source
Figure 1~2A
Figure 2B~2D
Figure 2E~2G
AI summary
Provided is a method for manufacturing a solar cell, comprising: providing a silicon substrate of a first conductivity type, and performing double-sided polishing on the silicon substrate; performing gettering treatment on the silicon substrate, comprising placing the silicon substrate in a gettering source to form a first silicon doped layer and a first silicon glass layer on a first surface of the silicon substrate and form a second silicon doped layer and a second silicon glass layer on a second surface of the silicon substrate opposite to the first surface; removing the first silicon glass layer; after the first silicon glass layer is removed, texturing the first surface of the silicon substrate, and removing the first silicon doped layer at the same time to form a textured surface on the first surface of the silicon substrate; removing at least a part of the second silicon glass layer and the second silicon doped layer; and smoothing the first surface of the silicon substrate.