Double-Layered Solar Cell Electrode Reducing Silver Consumption
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Solution Overview
Problem
Conventional solar cells face inefficiencies in carrier transfer due to high serial resistance and contact resistance, and high manufacturing costs associated with silver usage in electrode materials.
Innovation Solution
A solar cell design featuring a double-layered first electrode structure with a thicker first electrode layer and a thinner second electrode layer, where the first electrode layer is primarily silver and the second electrode layer is made from a less expensive conductive material, reducing serial resistance and contact resistance while minimizing silver usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layered silver electrode structure is used, then electrical conductivity is high, but manufacturing cost is high due to excessive silver consumption
Solution Approach 1:
The electrode is divided into two functional layers: a first electrode layer containing silver paste for electrical conductivity and adhesion, and a second electrode layer containing conductive ink for surface conductivity. This segmentation allows each layer to perform its specific function optimally while reducing overall silver consumption.
Solution Approach 2:
The first electrode layer is positioned at the interface with the semiconductor substrate where high conductivity and adhesion are critical, while the second electrode layer covers the broader surface area where lower-cost conductive material suffices. This local differentiation optimizes material placement based on functional requirements.
2Reliability
If a thicker electrode layer is used, then serial resistance is reduced, but manufacturing cost increases due to more material usage
Solution Approach 1:
The electrode combines silver-based paste and conductive ink in a composite structure. The silver paste provides bulk conductivity with lower resistance, while the conductive ink enhances surface conductivity. This composite approach reduces serial resistance without requiring excessive material thickness.
3Ease of manufacture
If conventional screen printing is used for electrode formation, then manufacturing process is simple, but manufacturing precision is limited
Solution Approach 1:
A release film is introduced as an intermediary carrier for the conductive ink. The ink is printed on the release film first, allowing precise pattern formation, then transferred to the substrate. This intermediary approach enables higher precision while maintaining process simplicity.
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 double-layered electrode structure enhances carrier transfer efficiency, improves solar cell performance, and decreases manufacturing costs by reducing silver consumption.
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.
Implementation Method 2
The first electrode layer and the at least one first current collector may contain the same material, for example, silver (Ag). The second electrode layer may contain a material different from the first electrode layer and the at least one first current collector.
Data Source
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 each including a first electrode layer connected to the emitter layer and a second electrode layer positioned on the first electrode 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. The first electrode layer has a first width and the second electrode layer has a second width less than the first width of the first electrode layer.