Solar Cell Anti-Reflective Layer Segmentation
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Solution Overview
Problem
Conventional solar cells lack an improved external appearance and high efficiency, particularly in CIGS-based solar cells with a PN hetero junction structure.
Innovation Solution
A solar cell design featuring a substrate with a back electrode layer, a light absorbing layer, and a window layer with an anti-reflective pattern and anti-reflective layers of different thicknesses, where the first anti-reflective layer is coated on one inclined surface and the second anti-reflective layer is coated on another inclined surface, both being integrally formed and having thickness differences to enhance appearance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional anti-reflective structure is used on the window layer, then the manufacturing process is simple, but the external appearance is poor and light incidence is insufficient
Solution Approach 1:
The anti-reflective layer is segmented into multiple layers with different thicknesses (first anti-reflective layer and second anti-reflective layer) positioned on different inclined surfaces of the anti-reflective pattern. This segmentation allows each layer to contribute differently to light interference, creating superior anti-reflective performance and enhanced external appearance compared to a single uniform layer.
Solution Approach 2:
Different regions of the anti-reflective pattern are assigned different local qualities through varying anti-reflective layer thicknesses. The first anti-reflective layer has a first thickness on the first inclined surface, while the second anti-reflective layer has a second thickness on the second inclined surface. This local variation optimizes light interference characteristics for different viewing angles and directions, improving overall external appearance and light incidence.
2Productivity
If a single uniform anti-reflective layer is used, then the manufacturing process is simple, but light incidence and efficiency are insufficient
Solution Approach 1:
The anti-reflective layer is divided into multiple segments (first and second anti-reflective layers) with different thicknesses positioned on different inclined surfaces. This segmentation enables optimized light interference across multiple wavelengths and viewing angles, significantly improving light incidence and solar cell efficiency compared to a single uniform layer.
Solution Approach 2:
The thickness parameter of the anti-reflective layer is varied across different regions and layers. The first anti-reflective layer has a first thickness while the second anti-reflective layer has a second thickness, creating different optical path lengths for light reflection. This parameter variation optimizes constructive and destructive interference effects across the solar spectrum, enhancing overall light absorption and cell efficiency.
3Productivity
If different thickness anti-reflective layers are used on different inclined surfaces, then light incidence and efficiency are improved, but the manufacturing precision requirement increases
Solution Approach 1:
The anti-reflective pattern with inclined surfaces is pre-formed on the window layer before applying the anti-reflective layers. This preliminary structuring creates well-defined geometric features (first and second inclined surfaces) that guide the subsequent deposition process, ensuring that the first and second anti-reflective layers are deposited on distinct, pre-determined surfaces with controlled thicknesses, thereby managing manufacturing precision requirements.
Solution Approach 2:
The manufacturing process is designed to apply different local qualities (different thicknesses) to different regions of the anti-reflective pattern. By targeting the first anti-reflective layer specifically on the first inclined surface and the second anti-reflective layer on the second inclined surface, the process achieves precise local thickness control, optimizing light interference characteristics while maintaining manufacturability through localized deposition techniques.
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 design provides an improved external appearance due to color change with viewing direction and increased light incidence, resulting in enhanced solar cell efficiency.
Implementation Method 1
the wavelength causing the constructive interference in the first anti-reflective layer is different from the wavelength causing the constructive interference in the second anti-reflective layer
Implementation Method 2
an anti-reflective layer provided on the window layer; wherein the anti-reflective layer has a first anti-reflective and a second anti-reflective layer
Data Source
Figure 1~3
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Figure 6~7
AI summary
Disclosed are a solar cell and a method of fabricating the same. The solar cell includes a back electrode layer; a light absorbing layer on the back electrode layer; a protrusion pattern on the light absorbing layer; a first anti-reflective layer having a first thickness on the protrusion pattern; and a second anti-reflective layer having a second thickness smaller than the first thickness on the protrusion pattern.