Textured Solar Cell Grid-Line Bonding With Partial AR Film Contact
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Solution Overview
Problem
Existing solar cells face issues with weak bonding between grid lines and solar cell slices, leading to a high probability of grid line detachment during usage.
Innovation Solution
The solar cell design incorporates a substrate with a first textured surface featuring pyramid structures, where grid-line areas with a second textured surface are formed. Sheet-shaped anti-reflection films are laser-treated onto the second textured surface, exposing portions and increasing contact area with the grid lines, which are then in contact with both the exposed surface and the anti-reflection films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grid lines are formed on the surface of solar cell slices using electroplating processes, then grid lines can be produced on the solar cell surface, but the bonding between grid lines and solar cell slices is weak and grid lines are likely to detach
Solution Approach 1:
The patent applies preliminary action by forming a textured surface on the solar cell slice before electroplating the grid lines. This pre-texturing creates an uneven surface with increased surface area and mechanical interlocking features, which prepares the substrate to provide stronger bonding for the subsequently deposited grid lines, thereby preventing detachment during usage.
2Productivity
If sheet-shaped anti-reflection films are formed on the second textured surface, then light reflection is reduced and photoelectric conversion efficiency is improved, but the contact area between grid lines and the substrate may be reduced
Solution Approach 1:
The patent applies local quality by selectively forming sheet-shaped anti-reflection films on specific regions of the second textured surface, particularly in areas where they will not interfere with grid line contact. This localized application maintains the anti-reflection benefit for photoelectric conversion while preserving adequate contact area between grid lines and the substrate in regions where the films are not applied.
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 design significantly enhances the bonding strength between grid lines and the substrate, reduces the likelihood of detachment, and improves the overall reliability and efficiency of the solar cell.
Implementation Method 1
Sheet-shaped anti-reflection films are laser-treated onto the second textured surface
Data Source
AI summary
Embodiments of the present disclosure relate to a solar cell and a method for producing the same. The solar cell includes: a substrate having a first textured surface, a plurality of sheet-shaped anti-reflection films, and a plurality of grid lines. A plurality of grid-line areas spaced from each other are formed on the first textured surface, and each grid-line area has a second textured surface. One or more sheet-shaped anti-reflection films of the plurality of sheet-shaped anti-reflection films are formed on a portion of the second textured surface of each grid-line area. Each grid line of the plurality of grid lines is formed on a respective grid-line area, and each grid line is in contact with the one or more sheet-shaped anti-reflection films and with a remaining portion of the second textured surface of the respective grid-line area not covered by any sheet-shaped anti-reflection films.