Solar Cell Array Interconnection via Thermal Insulating Zones
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing interconnected solar cells, particularly thin film polymer or organic solar cells, face challenges in alignment requirements, contamination, and geometric flexibility, limiting their scalability and cost-effectiveness in large-area production.
Innovation Solution
A method involving a continuous layer stack with selective heating to create insulating regions, reducing the need for material removal and alignment, allowing for roll-to-roll production in ambient conditions using benign solvents, and enabling flexible geometric layouts and high output voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to form insulating regions through material removal and ink deposition, then electrical isolation between cells is achieved, but alignment requirements become stringent and contamination increases
Solution Approach 1:
The patent replaces mechanical material removal and ink deposition processes with a thermal field-based approach. A heat-affected zone is created through controlled heating to transform the conductive layer into an insulating region, eliminating the need for precise mechanical alignment and ink deposition operations.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the conductive layer by applying thermal energy. The conductive layer is heated to a temperature that transforms its electrical properties from conductive to insulating, creating effective electrical isolation without requiring additional materials or precise alignment.
2Ease of manufacture
If multiple scribing and deposition steps are performed to create vias and conductive grids, then interconnections are formed, but manufacturing complexity and contamination risk increase
Solution Approach 1:
The patent merges multiple separate manufacturing steps (scribing, ink deposition, via formation, grid patterning) into a single integrated thermal processing step. The heat-affected zone simultaneously creates electrical isolation and defines interconnection regions, dramatically simplifying the manufacturing process.
Solution Approach 2:
The patent extracts and eliminates the need for multiple sequential steps by using thermal processing to directly create both insulating regions and conductive interconnections in one operation, removing the complexity of coordinating multiple scribing and deposition steps.
3Productivity
If traditional manufacturing methods are used, then solar cells can be produced, but geometric fill factor and layout flexibility are limited
Solution Approach 1:
The patent introduces dynamic control of the thermal processing parameters (heating temperature, duration, pattern) to enable flexible geometric configurations. The heat-affected zone can be dynamically adjusted to create various cell shapes, sizes, and arrangements, optimizing geometric fill factor while maintaining layout flexibility.
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 enhances the geometric fill factor, reduces contamination, and facilitates large-area, low-cost, stable production of solar cell arrays, achieving production levels of up to 1 gigawatt annually with improved alignment flexibility and reduced environmental impact.
Implementation Method 1
selectively heating the layer stack to a first depth equal to the prescribed thickness for obtaining a first heat affected zone at a first centre-to-centre distance from the contact hole, the first heat affected zone being transformed into a substantially insulating region with substantially the first depth in the layer stack, thereby locally providing an increased electrical resistivity to the layer stack
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Method of making an array of interconnected solar cells, including a) providing a continuous layer stack (1) of a prescribed thickness on a substrate (8), the layer stack (1) including an upper (2) and a lower (3) conductive layer having a photoactive layer (4) and a semiconducting electron transport layer (6) interposed there between; b) selectively removing the upper conductive layer (2) and the photoactive layer (4) for obtaining a contact hole (10) exposing the semiconducting electron transport layer (6); c) selectively heating the layer stack (1) to a first depth (dl) for obtaining a first heat affected zone (12) at a first centre-to-centre distance (sl) from the contact hole (10), the first heat affected zone (12) being transformed into a substantially insulating region with substantially the first depth (dl) in the layer stack, thereby locally providing an increased electrical resistivity to the layer stack (1).