Solar Cell Manufacturing with Dual-Function Insulation Film
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Solution Overview
Problem
The manufacturing process of back contact solar cells with textured light-receiving surfaces is complex due to the need for forming a protection layer on the back surface and subsequently removing it to create a textured structure, which complicates the process and increases the number of steps required.
Innovation Solution
A method that forms a texture structure on the light-receiving surface of a semiconductor substrate while using an insulation film to protect the back surface, which is then removed to form the insulation layer, thereby simplifying the process and reducing the number of manufacturing steps by utilizing the insulation film as both a protection layer and an insulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a protection layer is formed on the back surface and then removed to create a textured structure, then a textured light-receiving surface can be achieved, but the manufacturing process becomes complicated and the number of steps increases
Solution Approach 1:
The insulation film is given dual functionality: it serves as both the protection layer during texture formation and as the final insulation layer between electrodes. This eliminates the need for separate protection and insulation layers, reducing manufacturing steps while achieving the textured surface and electrical insulation requirements
Solution Approach 2:
The patent combines the protection layer and insulation layer into a single insulation film structure. By forming the insulation film before texture creation and retaining it through subsequent electrode formation, the patent merges two previously separate layers into one, simplifying the manufacturing process
2Shape
If a protection layer is formed on the back surface and then removed to create a textured structure, then a textured light-receiving surface can be achieved, but the number of manufacturing steps increases
Solution Approach 1:
The insulation film performs multiple functions throughout the manufacturing process: protecting the back surface during etching, serving as a mask for selective electrode formation, and providing final electrical insulation. This multi-functionality reduces the total number of manufacturing steps and improves production efficiency
Solution Approach 2:
The insulation film is formed in advance before the texture structure is created. This preliminary action allows the same film to protect the back surface during etching and later serve as the insulation layer, eliminating the need for subsequent protection layer removal and separate insulation layer formation steps
3Manufacturing precision
If the back surface is kept flat without texture structure, then precise formation of n-type and p-type semiconductor regions is facilitated, but light-receiving efficiency is reduced
Solution Approach 1:
The patent applies different surface characteristics to different regions: the light-receiving surface has a textured structure to enhance light absorption, while the back surface remains flat to facilitate precise semiconductor region formation. The insulation film enables this differential treatment by protecting only the back surface during texture formation
Data Source
AI summary
A solar cell is manufactured, which includes: a solar cell substrate including a semiconductor substrate, a p-type surface and an n-type surface exposed on a first principal surface, and a texture structure in a second principal surface; a p-side electrode disposed on the p-type surface; an n-side electrode disposed on the n-type surface; and an insulation layer formed on the first principal surface and isolating the p-side electrode and the n-side electrode from each other. The manufacturing method of the solar cell includes: forming an insulation film covering the first principal surface; forming the texture structure in the second principal surface; and removing part of the insulation film, thereby forming the insulation layer.