Solar Cell Electrode Grid Layout for Low-Resistance Metallization
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Solution Overview
Problem
Crystalline silicon solar cells face challenges in high production costs and limited photoelectric conversion efficiency due to large contact resistance between electrodes and silicon substrates, as well as the inaccuracies and high material usage of screen printing methods.
Innovation Solution
A solar cell design featuring fine-grids and main-grids with ohmic contact to the silicon substrate, where fine-grids are deposited and main-grids are formed by sintering electrode slurry, combining high-temperature and low-temperature metallization to reduce contact resistance and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing of silver slurry is used for metallization, then the manufacturing process is simple and easy to implement, but the contact resistance between electrodes and silicon substrate is large and production cost is high
Solution Approach 1:
The electrode structure is segmented into fine-grids and main-grids. The fine-grids provide extensive contact with the silicon substrate to reduce contact resistance, while the main-grids collect and transport current. This segmentation allows the electrode to simultaneously achieve low contact resistance through fine-grid substrate contact and efficient current collection through main-grid structures.
Solution Approach 2:
Different regions of the electrode structure are given different properties: the fine-grids are designed to maximize contact area with the silicon substrate for low contact resistance, while the main-grids are designed for optimal current collection and transport. This local differentiation of function optimizes both contact resistance and current collection efficiency.
2Ease of manufacture
If screen printing of silver slurry is used for metallization, then the manufacturing process is established and easy to implement, but the accuracy of electrode formation is limited and morphology is undulating
Solution Approach 1:
The patent replaces the mechanical screen printing process with a combination of deposition and sintering processes. The electrode slurry is deposited and then sintered to form the fine-grids and main-grids, which eliminates the undulating morphology issue inherent in screen printing while maintaining manufacturing feasibility through established thermal processing techniques.
3Reliability
If a large amount of silver slurry is used in screen printing, then the electrode coverage and conductivity are sufficient, but the production cost increases
Solution Approach 1:
The patent changes the physical and chemical parameters of the electrode formation process by using deposition and sintering instead of screen printing. This allows for more precise control of silver material distribution, forming conductive fine-grids and main-grids with optimized silver content that reduces overall slurry usage while maintaining sufficient conductivity through the interconnected grid structure.
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 solution achieves small contact resistance and high current collection efficiency, reducing production costs and improving solar cell performance by minimizing silver slurry usage and optimizing electrode structure.
Implementation Method 1
a plurality of fine-grids are deposited on the silicon substrate
Implementation Method 2
at least part of the main-grids are formed by sintering an electrode slurry
Implementation Method 3
performing heating treatment to the silicon substrate, to make the fine-grid have ohmic contact with the silicon substrate
Data Source
AI summary
A solar cell and a manufacturing method of the solar cell are provided. The solar cell includes a silicon substrate, the silicon substrate is deposited with a plurality of fine-grids, the plurality of fine-grids have ohmic contact with the silicon substrate; a plurality of main-grids are disposed on the silicon substrate; the plurality of main-grids intersect and electrically contact with the plurality of fine-grids; at least a part of the plurality of main-grids is formed by sintering an electrode slurry. The plurality of fine-grids and the plurality of main-grids are formed by a combination of a high temperature metallization (sintering) and a low temperature metallization (depositing), to overcome a high cost by using screen printing of silver slurry, in addition, due to the plurality of fine-grids having ohmic contact with the silicon substrate, the solar cell has advantages of small contact resistance and high current collection efficiency.