Solar Cell Emitter Layer Selective Laser Heating
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Solution Overview
Problem
The manufacturing process of solar cells is complex and costly, limiting the efficiency and cost-effectiveness of solar cell production.
Innovation Solution
A method for forming an emitter layer in solar cells involves diffusing a second impurity into a substrate to create a first emitter portion, followed by selective heating using laser beams to form a second emitter portion with higher impurity concentration and doped depth, which simplifies the manufacturing process and improves production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solar cell manufacturing processes are used, then the emitter layer can be formed with proper doping, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines the emitter layer formation and selective region creation into a single diffusion process. By applying a dopant-containing layer uniformly across the substrate and then selectively removing it in certain regions, the patent merges what would traditionally require separate doping and patterning steps into one integrated process, reducing manufacturing complexity while maintaining precision
Solution Approach 2:
The patent applies the dopant-containing layer across the entire substrate surface before any selective processing. This preliminary uniform application ensures that all regions receive the dopant simultaneously, and subsequent selective removal creates the desired pattern without requiring multiple doping steps, thereby simplifying the overall manufacturing process
2Manufacturing precision
If conventional solar cell manufacturing processes are used, then the emitter layer can be formed with proper doping, but production efficiency is reduced
Solution Approach 1:
The patent merges emitter formation and selective region definition into a single diffusion step. By uniformly applying the dopant source and then selectively removing portions, the process eliminates multiple sequential operations, reducing total processing time and improving production throughput while maintaining precise dopant placement
Solution Approach 2:
The patent maintains continuous dopant diffusion across the entire substrate surface during a single processing cycle. This continuous action, followed by selective removal, ensures that all regions are processed simultaneously rather than sequentially, maximizing equipment utilization and production efficiency
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 simplifies the solar cell manufacturing process, reducing costs and enhancing production efficiency by creating a solar cell with improved emitter layer characteristics that enhance electron collection and energy conversion efficiency.
Implementation Method 1
selectively heating a portion of the first emitter portion, which corresponds to a position for forming at least one electrode to form a second emitter portion
Implementation Method 2
diffusing a second impurity of a second conductive type opposite to the first conductive type in the substrate to form a first emitter portion
Data Source
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AI summary
A method for forming emitter layer of a solar cell includes preparing a substrate including a first impurity of a first conductive type, diffusing a second impurity of a second conductive type opposite to the first conductive type in the substrate to form a first emitter portion of the emitter layer in the substrate, and selectively heating a portion of the first emitter portion, which corresponds to a position for forming at least one electrode, to form a second emitter portion.