Method for producing layer structure for thin-film solar cells
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Solution Overview
Problem
Existing methods for determining the composition of the absorber layer in thin-film solar cells are inaccurate due to interference from the rear electrode layer, leading to reduced measurement accuracy and increased production costs, particularly in automated series production.
Innovation Solution
A method involving the creation of rear-electrode-layer-free regions on the rear electrode layer, allowing for precise measurement of the absorber layer composition using x-ray spectroscopy without interference, by laser ablation or decoating, and ensuring accurate process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sputtering methods are used to produce transparent conductive oxide layers, then the layers can be deposited, but the process requires high vacuum conditions and long deposition times which reduces productivity
Solution Approach 1:
The patent changes the deposition parameters by using pulsed laser deposition instead of conventional sputtering, allowing deposition at atmospheric pressure rather than high vacuum, and achieving faster deposition speeds while maintaining layer quality through controlled pulse parameters
Solution Approach 2:
The patent replaces the mechanical sputtering process with a laser-based pulsed deposition process, substituting mechanical energy transfer with photonic energy to achieve faster and more efficient layer deposition
2Manufacturing precision
If multiple separate deposition processes are used for different layers, then each layer can be optimized independently, but the overall manufacturing complexity and time increase
Solution Approach 1:
The patent creates a multi-functional deposition system that can deposit multiple different layers (transparent conductive oxide, buffer layer, semiconductor layer) using the same pulsed laser deposition apparatus, eliminating the need for separate processes while maintaining optimization capability
Solution Approach 2:
The patent combines multiple separate deposition processes into a single integrated pulsed laser deposition process, merging the equipment and process steps while maintaining the ability to independently control and optimize each layer's deposition parameters
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
Enables reliable and economical production of thin-film solar modules with high accuracy and reduced rejects, integrating seamlessly into automated series production without significant impact on module quality or efficiency.
Implementation Method 1
a pulsed laser is radiated onto a target (substrate or material to be deposited)
Implementation Method 2
depositing a semiconductor layer on the n-type buffer layer in an atmosphere of silicon monoxide
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A method for producing a layer structure for the production of thin-film solar cells that comprises the following steps: providing a carrier substrate (2), depositing a rear electrode layer (3) on the carrier substrate (2), producing at least one rear-electrode-layer-free region (5), creating a measurement layer (4) over the rear electrode layer (3) such that the measurement layer (4) is situated at least over the at least one rear-electrode-layer-free region (5), wherein the measurement layer (4) is a photoactive absorber layer (4) or a precursor layer of the photoactive absorber layer (4), determining a quantity or a relative share of at least one component of the measurement layer (4) in a region (9) of the measurement layer (4) that is situated over the at least one rear-electrode-layer-free region (5) of the rear electrode layer (3).