Textured Solar Cell Grid-Line Bonding With Anti-Reflection Films
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar cells face issues with weak bonding between grid lines and the solar cell substrate, leading to detachment during usage, which is not effectively addressed by conventional electrochemical methods.
Innovation Solution
The implementation of a solar cell design featuring a substrate with a first textured surface and multiple grid-line areas with a second textured surface, where sheet-shaped anti-reflection films are formed on the second textured surface to increase contact area and act as anchoring structures, enhancing bonding strength between grid lines and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional electrochemical methods are used to form grid lines on the solar cell surface, then the manufacturing process is simple, but the bonding strength between grid lines and substrate is weak leading to detachment
Solution Approach 1:
The substrate surface is pre-textured with pyramid structures before grid line formation. This preliminary texturing creates an increased surface area and mechanical interlocking features that enhance bonding strength when grid lines are subsequently deposited through electrochemical methods.
Solution Approach 2:
The invention transitions from a flat two-dimensional surface to a three-dimensional textured surface with pyramid structures. This dimensional change increases the effective bonding area and provides mechanical interlocking, thereby strengthening the bond between grid lines and substrate while preventing detachment.
2Strength
If the grid line contact area with substrate is increased to improve bonding, then the bonding strength improves, but the photoelectric conversion efficiency decreases due to reduced light-active area
Solution Approach 1:
The substrate surface is segmented into multiple pyramid structures distributed across the surface. This segmentation allows grid lines to bond with multiple discrete structures, increasing total bonding area without requiring a continuous large contact area, thus preserving light-active regions.
Solution Approach 2:
The pyramid structures are strategically distributed to provide localized bonding enhancement at grid line positions while maintaining large flat areas elsewhere for optimal light absorption and photoelectric conversion. This local quality differentiation resolves the conflict between bonding strength and energy 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 design significantly improves the bonding strength between grid lines and the substrate, reducing the probability of detachment and enhancing the reliability and photoelectric conversion efficiency of the solar cell.
Implementation Method 1
a first textured surface having a plurality of first pyramid structures
Implementation Method 2
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
Implementation Method 3
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 one or more sheet-shaped anti-reflection films formed on a portion of a second textured surface
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
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 (100) having a first textured surface, a plurality of sheet-shaped anti-reflection films (110), and a plurality of grid lines (120). 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 of the plurality of grid-line areas. 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. The solar cell and the method are at least conducive to improvement of the bonding strength between the plurality of grid lines and the substrate, and reduction of the probability of detachment of the plurality of grid lines from the substrate.