Solar Cell Module Edge Deletion via Segmented Laser Ablation
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Solution Overview
Problem
Current methods for manufacturing solar cell modules using laser technology face issues with shunts and cracks due to the removal of transparent conductive, photoelectric conversion, and back electrode layers, leading to reduced power generation performance and quality.
Innovation Solution
A method involving the use of two distinct laser beams with different properties to selectively remove the photoelectric conversion and back electrode layers from one region and the transparent electrode layer from another, ensuring the transparent substrate is not damaged and preventing shunts and cracks by spacing the removal regions appropriately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser beam is used to remove all layers (transparent conductive layer, photoelectric conversion layer, and back electrode layer) in the peripheral region, then the edge deletion process is simplified, but cracks are generated in the translucent substrate due to heat accumulation from laser reflection by the back electrode layer
Solution Approach 1:
The patent divides the laser beam irradiation process into two distinct steps: first irradiating to remove only the photoelectric conversion layer and back electrode layer, then second irradiating to remove the transparent conductive layer. This segmentation prevents heat accumulation and cracking by avoiding simultaneous removal of all layers, thus resolving the contradiction between process simplification and substrate integrity.
Solution Approach 2:
The patent performs preliminary removal of the photoelectric conversion layer and back electrode layer before removing the transparent conductive layer. This preliminary action eliminates the reflective back electrode layer that causes heat accumulation, thereby preventing cracks in the substrate during the subsequent removal of the transparent conductive layer.
2Productivity
If the laser beam is radiated to remove all layers in the peripheral region, then edge deletion is achieved, but shunts occur due to residues of the transparent conductive layer adhering to the walls of the groove
Solution Approach 1:
The patent segments the layer removal process into two stages: first removing the photoelectric conversion layer and back electrode layer, then removing the transparent conductive layer. This segmentation ensures that when the transparent conductive layer is removed, the groove walls are already free of other layers, preventing adhesion and shunt formation while maintaining edge deletion efficiency.
Solution Approach 2:
The patent performs preliminary removal of the photoelectric conversion layer and back electrode layer before removing the transparent conductive layer. This preliminary action creates a clean groove structure that prevents the transparent conductive layer residues from adhering to the walls, thereby preventing shunts while achieving complete edge deletion.
3Ease of manufacture
If sandblasting is used for edge deletion, then the thin films on the peripheral rim portion are removed, but powdered abrasives disperse in the power generation region causing low power generation performance and generating great amounts of dust
Solution Approach 1:
The patent replaces the mechanical sandblasting process with a laser beam irradiation process. This substitution eliminates the use of powdered abrasives, preventing their dispersion in the power generation region and the generation of dust, while still achieving effective edge deletion of the thin films.
4Ease of manufacture
If directly grinding with a rotating grinder is used for edge deletion, then thin films are removed, but productivity is reduced
Solution Approach 1:
The patent replaces the mechanical rotating grinder process with a laser beam irradiation process. This substitution eliminates the slow mechanical grinding operation and achieves rapid edge deletion through laser ablation, thereby significantly improving productivity while maintaining ease of manufacture.
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 effectively prevents shunts and cracks, enhancing the quality and power generation performance of solar cell modules by ensuring precise layer removal without damaging the substrate, and allows for a simpler and cost-effective laser beam irradiation apparatus.
Implementation Method 1
radiating a first laser beam to a multilayer body, which includes a transparent substrate and a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on the transparent substrate, from a side of the transparent substrate, to thereby remove the photoelectric conversion layer and the back electrode layer
Implementation Method 2
The transparent electrode layer in the second region irradiated with the second laser beam is removed by radiating a second laser beam having a property different from a property of the first laser beam into the first region such that the second laser beam is spaced from a peripheral rim of the first region
Data Source
AI summary
A method of manufacturing a solar cell, which includes an edge deletion step using a laser beam, and a manufacturing apparatus which is used in such a method, the method and the apparatus being capable of preventing a shunt and cracks from being generated are provided. By radiating a first laser beam to a multilayer body, which includes a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on a transparent substrate, from a side of the transparent substrate, the photoelectric conversion layer and the back electrode layer in a first region are removed, and by radiating a second laser beam into the region such that the second laser beam is spaced from a peripheral rim of the region, the transparent electrode layer in a second region is removed.