Solar Cell Collecting Electrode Plating via Self-Assembled Monolayer
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Solution Overview
Problem
Conventional methods for forming collecting electrodes in solar cells using plating techniques are costly and inefficient due to the need for resist materials, complex processes, and potential damage to the transparent electrode layer, leading to increased resistance and production costs.
Innovation Solution
A method involving a self-assembled monolayer on the transparent electrode layer, where a first electroconductive layer is formed, followed by a self-assembled monolayer formation on both electroconductive and non-electroconductive regions, allowing for selective removal and plating of a second electroconductive layer without a mask or resist, reducing resistance and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a silver paste is used to form a collecting electrode by screen printing, then the process is simple, but the material cost increases and the resistivity of the collecting electrode increases
Solution Approach 1:
A self-assembled monolayer is introduced as an intermediary substance between the transparent electrode layer and the plating solution. This monolayer selectively allows copper ions to pass through to the electroconductive layer while preventing direct contact between the plating solution and the transparent electrode layer, thereby enabling low-resistance electrode formation without damaging the underlying structure
Solution Approach 2:
The patent replaces the mechanical screen printing process with an electrochemical plating process. Instead of physically depositing silver paste through a screen, copper ions are electrochemically reduced and deposited onto the electroconductive layer, achieving lower resistivity through a different physical mechanism
2Productivity
If the transparent electrode layer is directly contacted with plating solution, then the plating process is simple, but the transparent electrode layer is damaged and solar cell characteristics are degraded
Solution Approach 1:
The self-assembled monolayer serves as a protective intermediary that mediates between the plating solution and the transparent electrode layer. It allows the plating process to proceed efficiently while preventing direct harmful contact between the aggressive plating solution and the sensitive transparent electrode layer
Solution Approach 2:
The self-assembled monolayer creates a protective interface that copies or mimics the desired selective permeability - allowing copper ions to pass through while blocking other components of the plating solution, thereby protecting the transparent electrode layer without interfering with the plating process
3Manufacturing precision
If a resist material layer is formed before plating, then the collecting electrode shape can be controlled, but the process complexity and production cost increase
Solution Approach 1:
The self-assembled monolayer performs multiple functions automatically: it provides shape control through its deposition pattern, acts as a protective barrier, and enables selective ion transport. This self-service capability eliminates the need for separate resist material application and removal steps, reducing process complexity while maintaining manufacturing precision
Solution Approach 2:
The self-assembled monolayer serves multiple functions simultaneously: it acts as a shape-defining mask, a protective barrier against plating solution damage, and a selective ion transport membrane. This multi-functionality consolidates what would otherwise require multiple separate process steps, reducing overall process complexity
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 approach enables the formation of collecting electrodes with lower resistance and reduced production costs, improving the productivity and efficiency of solar cell manufacturing by eliminating the need for complex patterning processes and protecting the transparent electrode layer from plating solutions.
Implementation Method 1
a self-assembled monolayer is formed on a region of a surface of the transparent electrode layer
Implementation Method 2
The self-assembled monolayer (abbreviated as SAM) refers to a monolayer formed such that when a so-called self-assembling compound is adsorbed (chemisorbed) on a specific base material surface
Implementation Method 3
a metallic layer made of copper or the like is formed by a plating method on a transparent electrode layer that forms a photoelectric conversion section
Implementation Method 4
a metallic layer is formed at the resist opening section of the transparent electrode layer by electroplating
Data Source
AI summary
In a solar cell, a collecting electrode is provided on a transparent electrode of a photoelectric conversion section having the transparent electrode on the outermost surface on one main surface side. The collecting electrode includes a first electroconductive layer and a second electroconductive layer in this order from the photoelectric conversion section side. Preferably, a self-assembled monolayer is formed on a region on the transparent electrode layer, which is not provided with the first electroconductive layer. A method for manufacturing the solar cell includes: forming a first electroconductive layer on a transparent electrode layer; forming a self-assembled monolayer on a region on the transparent electrode layer, which is not provided with the first electroconductive layer; and bringing the first electroconductive layer and a plating solution into contact with each other to form the second electroconductive layer by a plating method, in this order.