Solar Cell Electrode Layout for Reliable Multi-Busbar Contacts
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Solution Overview
Problem
The reduction in electrode pad area in multi-busbar technology for photovoltaic cells leads to unreliable connections with busbars and reduced current collection capability, making it difficult to simultaneously minimize unit consumption and ensure connection reliability.
Innovation Solution
A photovoltaic solar cell design featuring a silicon substrate with a passivation layer, an electrode, electrode pad, and extension line, where the extension line connects the busbar and electrode pad, maintaining contact with the silicon substrate to enhance reliability and current collection, while being printed using non-fire-through and fire-through pastes to prevent grid breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the area of electrode pad is reduced to decrease metallization unit consumption, then unit consumption is reduced, but connection reliability between electrode pad and busbar deteriorates
Solution Approach 1:
The invention divides the connection path into multiple segments: electrode pad → extension line → busbar. The extension line is separated from both the electrode pad and busbar, creating distinct functional zones. This segmentation allows the electrode pad area to be reduced while the extension line provides a distributed connection path that maintains overall connection reliability.
Solution Approach 2:
The extension line acts as an intermediary element between the electrode pad and busbar. It is in direct contact with the silicon substrate while being electrically connected to both the electrode pad and busbar, providing a mediating connection path that ensures reliability even when the electrode pad area is reduced.
2Loss of substance
If the area of electrode pad is reduced to decrease metallization unit consumption, then unit consumption is reduced, but current collection capability deteriorates
Solution Approach 1:
The invention transitions from a two-dimensional electrode pad surface contact to a three-dimensional connection structure. The extension line extends vertically from the electrode pad through the passivation layer to contact the silicon substrate, creating a vertical current collection path that compensates for the reduced horizontal electrode pad area.
Solution Approach 2:
The extension line serves as an intermediary that provides additional current collection pathways. By contacting the silicon substrate directly and connecting to the electrode pad, it creates parallel current collection routes that maintain overall current collection capability despite the reduced electrode pad area.
3Reliability
If extension line is introduced to improve connection reliability, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The extension line is integrated with the existing electrode and electrode pad structures through electrical connections. It merges the functions of connection and current collection into a single element that works in conjunction with the existing components, rather than adding a completely separate system.
Solution Approach 2:
The extension line performs multiple functions: it provides a connection path between the electrode pad and busbar, serves as an additional current collection element by contacting the silicon substrate, and protects against grid breakage. This multi-functionality justifies the added structural element by delivering multiple benefits from a single addition.
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 design reduces unit consumption while ensuring reliable connections between the electrode pad and busbar, maintaining effective current collection even when the electrode is eroded by welding alloys, thus preventing grid breakage and enhancing overall performance.
Implementation Method 1
Two ends of the extension line are connected to the busbar and the electrode pad, respectively... the extension line is in direct contact with the passivation layer
Data Source
AI summary
Provided is a photovoltaic solar cell, a solar cell module and a manufacturing process. The photovoltaic solar cell includes a silicon substrate, and a passivation layer located on at least one surface of the silicon substrate. An electrode, an electrode pad and an extension line are printed on at least one surface of the silicon substrate. The electrode includes a busbar and a finger crossed with each other, and the finger is in contact with the silicon substrate. Two ends of the extension line are respectively connected to the busbar and the electrode pad, to reinforce a connection between the busbar and the electrode pad such that the extension line is not in direct contact with the finger, the extension line is in contact with the passivation layer, the electrode pad and the busbar are not in direct contact with the silicon substrate.