Multi-layered Solar Cell Electrode Structure for Reduced Serial Resistance
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Solution Overview
Problem
Conventional solar cells face inefficiencies in carrier transfer and high manufacturing costs due to high serial resistance and excessive silver usage in electrode structures.
Innovation Solution
A solar cell design featuring a substrate of a first conductive type with an emitter layer of a second conductive type, multi-layered first electrodes with a higher silver content, and a single-layered first current collector, along with a second electrode layer positioned on the first electrode or current collector, reducing serial resistance and using less expensive conductive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layered electrode structure is used, then the manufacturing process is simple, but the serial resistance is high and carrier transfer efficiency is low
Solution Approach 1:
The electrode is divided into two distinct layers: a first electrode layer containing silver paste for low-resistance electrical connection, and a second electrode layer containing conductive material for current collection. This segmentation allows each layer to perform its specific function optimally, reducing overall serial resistance while maintaining manufacturing simplicity through sequential printing processes.
Solution Approach 2:
The multi-layered electrode structure combines different materials with complementary properties: the first electrode layer uses silver-rich paste for high conductivity, while the second electrode layer uses conductive material for current collection. This composite structure achieves superior electrical performance compared to single-layer designs.
2Reliability
If high silver content is used in electrodes, then the electrical conductivity is improved, but the manufacturing cost increases
Solution Approach 1:
Silver is concentrated in the first electrode layer where high conductivity is critical for electrical connection to the emitter layer. The second electrode layer uses less expensive conductive material, creating a local quality distribution that optimizes silver usage - high silver content where needed, lower silver content where sufficient conductivity can be achieved with alternative materials.
Solution Approach 2:
The patent replaces some expensive silver material with cheaper conductive materials in the second electrode layer, reducing overall silver consumption and manufacturing cost while maintaining sufficient electrical performance through the layered architecture.
3Reliability
If thick electrodes are used, then the serial resistance is reduced, but the light absorption area is decreased
Solution Approach 1:
Instead of increasing electrode thickness in one dimension, the solution transitions to a multi-layered vertical structure. The first electrode layer provides low-resistance connection close to the emitter, while the second electrode layer extends for current collection. This dimensional approach reduces serial resistance without requiring excessive thickness that would block light.
Solution Approach 2:
The multi-layered composite electrode structure achieves low serial resistance through the combined effect of two layers with different material properties and thicknesses, avoiding the need for a single thick electrode that would obstruct light absorption.
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 design enhances carrier transfer efficiency, improves solar cell efficiency, and reduces manufacturing costs by optimizing silver usage and electrode structure.
Implementation Method 1
When light is incident on the solar cell, a plurality of electron-hole pairs are generated in the semiconductor parts. The electron-hole pairs are separated into electrons and holes by the photovoltaic effect.
Data Source
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Figure 3(a)~3(c)
AI summary
A solar cell and a method for manufacturing the same are discussed. The solar cell includes a substrate of a first conductive type, an emitter layer of a second conductive type opposite the first conductive type, a plurality of first electrodes connected to the emitter layer, at least one first current collector connected to the plurality of first electrodes, and a second electrode connected to the substrate. The emitter layer forms a p-n junction along with the substrate. Each of the plurality of first electrodes has a multi-layered structure, and the at least one first current collector has a single-layered structure.