Solar Cell Module Insulating Pattern Eliminates Patterning
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Solution Overview
Problem
The manufacturing of thin-film solar cell modules is hindered by the time-consuming patterning process required for the deposition and subsequent patterning of the bottom electrode, photoelectric conversion layer, and top electrode, which complicates the assembly of solar cell modules.
Innovation Solution
A solar cell module structure is introduced, featuring a bottom electrode, photoelectric conversion layer, insulating pattern, top electrode layer, and passivation layer, where a sufficiently thick insulating pattern on the bottom electrode divides subsequent deposited films, eliminating the need for patterning, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional deposition and patterning process is used for each layer (bottom electrode, photoelectric conversion layer, top electrode), then each layer can be formed with proper structure, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The insulating pattern is formed on the bottom electrode before depositing the photoelectric conversion layer and top electrode. This preliminary insulating structure acts as a mask that automatically defines the patterns of subsequent layers during deposition, eliminating the need for separate patterning steps for each layer and significantly reducing manufacturing time
Solution Approach 2:
The insulating pattern divides the bottom electrode into distinct regions, creating isolated active areas for each solar cell. This segmentation allows subsequent deposited films to be automatically divided by the insulating patterns, enabling parallel processing and eliminating sequential patterning operations
2Manufacturing precision
If multiple patterning processes are performed for each deposited layer, then precise layer patterns are achieved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The insulating pattern is prepared in advance on the bottom electrode, serving as a permanent mask structure. This preliminary structure guides the deposition of all subsequent layers, eliminating the need for multiple patterning processes and reducing manufacturing process complexity while maintaining pattern precision
Solution Approach 2:
The insulating pattern serves multiple functions: it electrically isolates adjacent solar cells, defines the pattern boundaries for subsequent layers, and acts as a physical mask during deposition. This multi-functionality eliminates the need for separate patterning operations for each layer, simplifying the overall manufacturing 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
This approach simplifies the manufacturing of solar cell modules by eliminating the need for patterning of deposited films, enhancing efficiency and reducing production time.
Implementation Method 1
a photoelectric conversion layer between them
Implementation Method 2
each of the bottom electrode, the photoelectric conversion layer and the top electrode is formed with a deposition process
Data Source
AI summary
A solar cell module is described, including a series of solar cells each including a bottom electrode, a photoelectric conversion layer, an insulating pattern, a top electrode layer and a passivation layer. The conversion layer is on the bottom electrode and also on the substrate at a first side of the bottom electrode. The insulating pattern is on the bottom electrode, covering an edge portion of the conversion layer near a second side of the bottom electrode. The top electrode layer is on the conversion layer and adjacent to the insulating pattern. The passivation layer is on the top electrode layer and adjacent to the insulating pattern, wherein the top of the passivation layer on the top electrode layer is lower than the top of the insulating pattern. The bottom electrode of a solar cell is electrically connected with the top electrode layer of an adjacent solar cell.