Back-Contact Solar Cell Emitter Patterning by Surface Wetting
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Solution Overview
Problem
The formation of emitter regions in back-contact solar cells is cumbersome and complex, affecting the efficiency and cost-effectiveness of solar cell manufacturing.
Innovation Solution
A method involving surface treatment of a silicon substrate to create lyophilic areas between lyophobic areas, followed by depositing a liquid phase material to form emitter regions, such as a silane-type polymer, which allows for controlled formation of P-type and N-type emitter fingers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to form emitter regions in back-contact solar cells, then the p-n junction structure can be formed, but the manufacturing process becomes cumbersome and complex
Solution Approach 1:
The patent changes the physical and chemical parameters of the silicon substrate surface by creating regions with different surface energies (lyophilic and lyophobic areas). This allows the liquid phase material to selectively deposit only in the lyophilic regions, automatically forming precisely defined emitter regions without complex masking or patterning steps.
Solution Approach 2:
The surface treatment creates self-directing properties where the liquid phase material automatically deposits only in the desired lyophilic regions due to surface energy differences. The system self-organizes the emitter region formation without requiring external guidance or complex process control, simplifying the manufacturing process while maintaining precision.
2Reliability
If conventional emitter region formation methods are used, then doped regions can be created, but the manufacturing cost increases and efficiency decreases
Solution Approach 1:
The patent replaces complex mechanical or chemical patterning processes with a surface energy-based selective deposition mechanism. By treating the substrate surface to create lyophilic and lyophobic areas, the liquid phase material automatically deposits only where needed, eliminating the need for complex masking, etching, or doping processes while maintaining reliable emitter region formation.
3Manufacturing precision
If surface treatment is applied to create lyophilic areas, then precise emitter region structures can be formed, but additional processing steps are required
Solution Approach 1:
The surface treatment is performed as a preliminary step before material deposition, creating the lyophilic and lyophobic pattern on the substrate surface. This pre-prepared surface structure guides the subsequent liquid phase material deposition, ensuring precise emitter region formation in a single step without requiring additional patterning or masking operations during the deposition process.
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
Facilitates the low-cost and efficient production of back-contact solar cells with precise emitter region structures, enhancing their performance and reliability.
Implementation Method 1
treating a surface of a silicon substrate to form a lyophilic area between two lyophobic areas
Implementation Method 2
depositing a liquid phase material, e.g., a silane-type polymer, on the surface in the lyophilic area to form an emitter region
Data Source
AI summary
Methods of fabricating emitter regions of solar cells using surface treatments, and the resulting solar cells, are described herein. In an example, a method of fabricating a solar cell includes treating a surface of a silicon substrate to form a lyophilic area between two lyophobic areas and depositing a liquid phase material containing a silicon material in the lyophilic area to form an emitter region.