Solar Cell Buffer Layer Enhances Substrate Bonding
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Solution Overview
Problem
The existing solar cell manufacturing process faces issues with poor bonding between the light absorption layer and the rear electrode layer or support substrate, leading to peeling off of the light absorption layer, which increases electrical resistance and reduces photovoltaic efficiency.
Innovation Solution
A solar cell structure is developed with protrusions on the exposed top face of the support substrate through through-grooves, where the protrusions are made of a mixture of molybdenum and molybdenum diselenide, with a content configuration that increases molybdenum diselenide towards the light absorption layer, enhancing the bonding force between the light absorption layer and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the light absorption layer is formed directly on the patterned rear electrode layer, then the manufacturing process is simple, but the bonding force between layers is poor causing peeling
Solution Approach 1:
A buffer layer comprising zinc oxide is introduced between the light absorption layer and the patterned rear electrode layer. This intermediary buffer layer improves the bonding force between the light absorption layer and the substrate, preventing peeling while maintaining manufacturing simplicity. The buffer layer acts as a mediator that enhances adhesion without complicating the overall manufacturing process.
2Strength
If the light absorption layer is formed on the support substrate through through-grooves, then bonding to substrate is improved, but manufacturing complexity increases
Solution Approach 1:
Through-grooves are formed in the rear electrode layer before depositing the light absorption layer, and protrusions are prepared on the support substrate in advance. This preliminary preparation enables the light absorption layer to form strong bonds with the substrate through the groove structures, while the buffer layer fills these grooves to maintain structural integrity and reduce overall device complexity.
3Ease of manufacture
If the light absorption layer peels off from the rear electrode layer, then manufacturing is simple, but electrical resistance increases and photovoltaic efficiency deteriorates
Solution Approach 1:
The buffer layer comprising zinc oxide serves as an intermediary that prevents peeling between the light absorption layer and the patterned rear electrode layer. This intermediary structure maintains strong bonding throughout the device operation, ensuring low electrical resistance and high photovoltaic efficiency without complicating the manufacturing process.
Solution Approach 2:
The buffer layer is deposited beforehand to cushion and prevent the peeling issue before it occurs. By preparing this adhesion-enhancing layer in advance, the patent prevents the formation of poor bonds that would lead to peeling, maintaining both manufacturing simplicity and device reliability.
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 configuration prevents the light absorption layer from peeling off, thereby improving the overall photovoltaic efficiency of the solar cells by enhancing the bonding force between the support substrate and the light absorption layer.
Implementation Method 1
the buffer layer comprises zinc oxide and enhances a bonding force between the light absorption layer and the substrate
Data Source
AI summary
The present disclosure provides a solar cell device comprising; a support substrate; a rear electrode layer on the substrate; a light absorption layer on the rear electrode layer; a front electrode layer on the light absorption layer; and wherein a first through-hole is defined in the rear electrode layer; wherein at least one protrusion is formed on an exposed top face of the substrate via the first through-hole.