Solar Cell Damage Buffer for Laser Metallization
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Solution Overview
Problem
Existing solar cell fabrication methods face challenges in minimizing damage during the bonding and patterning processes, which can affect the efficiency and reliability of the solar cells.
Innovation Solution
The use of damage buffers, such as polyimide with titanium oxide filters, is introduced to inhibit damage from laser tools during the bonding and patterning of conductive foils, allowing for in-situ laser welding and ablation processes, and enabling the formation of metal fingers using pre-fabricated metal foils, reducing fabrication costs and minimizing residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser tools are used for bonding and patterning conductive foils, then productivity and manufacturing precision are improved, but damage to underlying solar cell structures occurs
Solution Approach 1:
A damage buffer layer is introduced as an intermediary between the laser tool and the underlying solar cell structures. This buffer layer absorbs or dissipates the harmful laser energy, preventing damage to the semiconductor substrate and metallization layers while allowing the laser bonding and patterning processes to proceed effectively.
Solution Approach 2:
The damage buffer layer is applied beforehand to the solar cell structure before the laser bonding and patterning operations. This pre-applied protective layer acts as a cushion against the impending laser exposure, absorbing the harmful effects before they can reach and damage the underlying sensitive structures.
2Ease of manufacture
If pre-fabricated metal foils are used for conductive layers, then manufacturing cost is reduced, but damage during bonding process occurs
Solution Approach 1:
The damage buffer layer serves as a mediator that enables the use of pre-fabricated metal foils by protecting the underlying structures during the bonding process. This allows the cost-effective pre-fabricated foil approach to be used without compromising the integrity of the solar cell structures.
Solution Approach 2:
By applying the damage buffer layer before the bonding process, the patent enables the use of pre-fabricated metal foils while protecting against bonding-induced damage. The cushioning effect allows standard bonding processes to be used without causing harm to the underlying structures.
3Device complexity
If traditional fabrication methods are used without damage buffers, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to laser damage
Solution Approach 1:
The damage buffer layer acts as a simple intermediary that significantly improves manufacturing precision and reliability. By adding this single protective layer, the patent enables high-precision laser bonding and patterning operations without the complexity of multiple protective measures or process adjustments.
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 enhances the reliability and efficiency of solar cell fabrication by reducing damage to underlying structures, allowing for cost-effective production with reduced residue and improved solar cell performance.
Implementation Method 1
damage buffers, such as polyimide with titanium oxide filters, is introduced to inhibit damage from laser tools during the bonding and patterning processes
Implementation Method 2
allowing for in-situ laser welding and ablation processes
Implementation Method 3
allowing for in-situ laser welding and ablation processes
Data Source
AI summary
A solar cell structure includes a semiconductor region disposed in or above a substrate. A damage buffer can be disposed above the semiconductor region. First and second conductive layers can be bonded together at a location above the damage buffer.