Solar Cell Substrate Joining via Hot Pressing
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Solution Overview
Problem
Chip-type solar cells have inefficiencies in electricity generation due to high production energy consumption and light reflection losses, while thin-film solar cells face challenges in maximizing sunlight absorption without using cadmium-based materials.
Innovation Solution
A method involving the formation of transparent and absorbing layers on substrates using hot pressing, laser scribing, and chemical bath deposition, with the integration of selenium selenization to enhance efficiency and eliminate cadmium usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If chip-type solar cells are used, then manufacturing precision can be achieved through conventional processes, but energy consumption exceeds electricity generation and light reflection losses occur
Solution Approach 1:
The patent changes the physical and chemical parameters of the solar cell structure by using thin-film materials with specific optical properties (refractive indices) and controlling layer thicknesses to optimize light absorption while reducing reflection losses
Solution Approach 2:
The patent employs composite material structures including multiple layers of different semiconductor materials (CIS, CIGS) and buffer layers (CdS, ZnO) with varying optical and electrical properties to enhance overall light absorption efficiency
2Loss of energy
If thin-film solar cells with CdS buffer layer are used, then absorption efficiency is improved, but environmental pollution increases due to cadmium usage
Solution Approach 1:
The patent extracts and removes the harmful cadmium-containing buffer layer from the solar cell structure, replacing it with environmentally friendly alternative materials that maintain or improve absorption efficiency
Solution Approach 2:
The patent changes the material composition parameters by substituting cadmium-based compounds with non-toxic alternatives such as zinc oxide or indium oxide buffer layers, thereby eliminating environmental pollution while preserving optical absorption properties
3Device complexity
If multiple layers are formed on a single substrate, then device complexity is reduced, but manufacturing precision and quality control become difficult
Solution Approach 1:
The patent segments the manufacturing process by forming different functional layers on separate substrates independently, then joining the substrates together. This allows each layer to be optimized and controlled separately while maintaining overall device performance
Solution Approach 2:
The patent transitions from a planar single-substrate structure to a multi-substrate stacked configuration, adding the dimension of vertical layering with independent substrates that can be precisely joined through edge alignment and bonding
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 method enhances solar cell efficiency by optimizing layer formation and sunlight absorption, reducing energy consumption, and providing an environmentally friendly cadmium-free production process.
Implementation Method 1
The joining device is used to join together the first and second substrates by joining the transparent electrode layer with the absorbing layer
Implementation Method 2
the operation of the solar cells is based on semiconductor materials that generate electricity after they absorb sun light
Implementation Method 3
the anti-reflection layer 96 can be made of MgF2 for example to increase the proportion of the sun light that enters the solar cell 9
Implementation Method 4
The CdS layer 93 can be called the 'buffering layer' to increase the absorption efficiency
Data Source
AI summary
Disclosed is a method for making a solar cell. In the method, there are provided first and second substrates each including first and second faces. There are provided first and second coating devices and a joining device. The first coating device is used to form a transparent electrode layer on the first face of the first substrate. The second coating device is used to form an absorbing layer on the first face of the second substrate. The second substrate is selenized by hot pressing. The joining device is used to join together the first and second substrates by joining the transparent electrode layer with the absorbing layer. The transparent electrode layer is joined with the absorbing layer by hot pressing. Thus, the solar cell is not made by coating one layer on another. Time for making the solar cell is reduced.