Compound Semiconductor Solar Cell Defect Isolation

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Solution Overview

Problem

Compound semiconductor solar cells face efficiency reduction due to defect portions formed during manufacturing, which cause leakage currents and potential short circuits, necessitating an effective method for isolating these defects.

Innovation Solution

A compound semiconductor solar cell design incorporating a defect portion surrounded by an isolation portion, formed using etching processes with specific etching solutions and protective layers, minimizes the size of the isolation area and reduces light incident loss, allowing for efficient defect isolation without additional processing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a large isolation portion is formed around the defect portion, then the defect isolation effectiveness is improved, but the light incident area is reduced and efficiency is worsened

Engineering Contradiction:

Improvedefect isolation effectivenessVSAvoidlight incident loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies local quality by forming an isolation portion with non-uniform width around the defect portion. The isolation portion has a larger width at the defect portion location and gradually narrows toward the edges, creating localized isolation effectiveness where most needed while preserving light incident area in peripheral regions. This gradient structure optimizes the balance between defect isolation and light absorption.

Inventive Principle:

Principle #3Local quality

2Reliability

If the compound semiconductor layer is completely removed around the defect portion, then the defect isolation is improved, but the structural integrity and electrical connection are worsened

Engineering Contradiction:

Improvedefect isolationVSAvoidstructural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies preliminary action by forming the isolation portion before completing the removal of the compound semiconductor layer. The isolation portion is created as an intermediate structure that progressively isolates the defect portion while maintaining structural continuity. This staged approach allows defect isolation to be achieved without completely removing the semiconductor layer, thereby preserving structural integrity and electrical connections.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If additional processing steps are added to isolate defect portions, then the defect isolation effectiveness is improved, but the manufacturing complexity and cost are worsened

Engineering Contradiction:

Improvedefect isolation effectivenessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies merging by combining the defect isolation function with the existing compound semiconductor layer structure. Instead of adding separate isolation layers or structures, the isolation portion is formed by selectively modifying the existing semiconductor layer through controlled removal or thinning. This integration approach achieves defect isolation without introducing additional processing steps or complex manufacturing procedures.

Inventive Principle:

Principle #5Merging (Combining)

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

The method effectively isolates defect portions, enhancing the solar cell's efficiency by minimizing light loss and reducing the number of unusable finger electrodes, thereby improving overall performance and reducing the risk of short circuits.

Implementation Method 1

performing a first etching process using the first etching solution or the second etching solution that has a high selectivity to the first compound semiconductor or the second compound semiconductor forming a layer positioned at an uppermost part of the protective layer; performing a second etching process using the second etching solution or the first etching solution

Methodology Applied

Scientific EffectChemical etching: Ablation

Implementation Method 2

forming a protective layer including a single layer or at least two layers at the uppermost layer of the compound semiconductor layer, the single layer being formed of a second compound semiconductor that has a high selectivity to the second etching solution

Methodology Applied

Scientific EffectSelective etching resistance:

Data Source

PatentUS10861991B2Compound semiconductor solar cell and method of manufacturing the same

Publication Date: 2020.12.08 TRINA SOLAR CO LTD

AI summary

A compound semiconductor solar cell and a method of manufacturing the same are disclosed. The compound semiconductor solar cell includes a compound semiconductor layer, a front electrode positioned on a front surface of the compound semiconductor layer, a back electrode positioned on a back surface of the compound semiconductor layer, a defect portion disposed within the compound semiconductor layer and physically and electrically connected to the back electrode, and an isolation portion surrounding the defect portion.