Solar Cell Conductor Transfer Using Grooved Flexible Membranes
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Solution Overview
Problem
Existing methods for forming conductors on solar cells face limitations in line resolution and exact placement, often requiring cumbersome batch processing and separate processing of each side of the solar cell.
Innovation Solution
A method involving a flexible membrane with a pattern of grooves is used to apply a composition of electrically conductive particles and adhesive to the solar cell substrate, where the composition is sintered to create conductive patterns, allowing for precise conductor placement and application to both sides of the cell in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known methods of forming conductors on solar cells are used, then conductors can be applied to the solar cell, but line resolution and exact placement are limited
Solution Approach 1:
The patent uses a flexible membrane with grooves to transfer conductor composition onto the solar cell. This flexible thin film approach enables precise placement and high line resolution while simplifying the overall process compared to traditional batch processing methods
Solution Approach 2:
The groove pattern on the flexible membrane serves as a template or copy that is transferred to the solar cell surface. This copying mechanism ensures exact placement and consistent line resolution across multiple solar cells without requiring complex positioning systems
2Productivity
If batch processing is used to apply conductors to solar cells, then conductors can be applied, but the process is cumbersome and time-consuming
Solution Approach 1:
The flexible membrane method enables continuous processing where the membrane can be repeatedly used to transfer conductor patterns. This eliminates the need for separate batch processing steps and allows continuous application of conductors to multiple solar cells, significantly improving productivity and reducing processing time
3Productivity
If each side of the solar cell is processed separately, then conductors can be applied to both sides, but the process requires multiple separate steps
Solution Approach 1:
The patent combines the processing of both sides of the solar cell into a single operation using the flexible membrane method. The membrane can be applied to one side, processed, and then the same or another membrane can be applied to the opposite side without requiring separate batch processing equipment or procedures, thereby merging multiple steps into a unified process
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 precision and efficiency of conductor application on solar cells, improving line resolution and enabling continuous contact across non-planar substrates, thus facilitating the production of high-efficiency solar cells and modules.
Implementation Method 1
applying sufficient energy to sinter the electrically conductive particles in order to render electrically conductive the pattern of composition transferred to the substrate from the grooves
Implementation Method 2
applying pressure to the membrane to cause the composition loaded into the grooves in the first surface of the membrane to adhere to the substrate
Data Source
AI summary
A method is disclosed for applying an electrical conductor to a solar cell, which comprises providing a flexible membrane with a pattern of groove formed on a first surface thereof, and loading the grooves with a composition comprising conductive particles. The composition is, or may be made, electrically conductive. Once the membrane is loaded, the grooved first surface of the membrane is brought into contact with a front or/and back of a solar cell. A pressure is then applied between the solar cell and the membrane(s) so that the composition loaded to the grooves adheres to the solar cell. The membrane(s) and the solar cell are separated and the composition in the groove is left on the solar cell surface. The electrically conductive particles in the composition are then sintered or otherwise fused to form a pattern of electrical conductor on the solar cell, the pattern corresponding to the pattern formed in the membrane(s).