Solar Cell Metal Electrodes Using Laser-Etched Masks for Low-Shading PVD
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Solution Overview
Problem
Existing solar cell electrode manufacturing methods, particularly silver paste screen printing, are costly due to high silver consumption, low conductivity, and result in significant sunlight blocking and low yield, especially in thin film solar cells.
Innovation Solution
A laser-etched polymer film mask is used to create precise metal electrodes via physical vapor deposition, allowing for thin, high-conductivity electrodes with reduced shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver paste screen printing is used to manufacture electrodes, then conductivity is achieved, but cost increases significantly and line width becomes too thick (more than 30 μm)
Solution Approach 1:
The patent replaces the mechanical screen printing process with a physical vapor deposition (PVD) system. The PVD process deposits metal vapor directly onto the substrate through vacuum deposition, enabling precise control of metal thickness and pattern without the need for thick paste layers. This substitution of manufacturing mechanism achieves both high conductivity and reduced material consumption.
Solution Approach 2:
The patent changes the deposition parameters by using PVD technology with controlled vapor deposition rates and substrate temperatures. By adjusting these parameters, the process achieves thin metal lines (1-10 μm) with high conductivity, replacing the traditional thick paste application method. The parameter control enables precise line width management while maintaining electrical performance.
2Reliability
If thick electrode grids are used to achieve certain conductivity, then conductivity requirement is met, but more sunlight is blocked and cost increases
Solution Approach 1:
The patent changes the physical state and deposition parameters of the metal electrode. By using PVD to create thin metal layers (1-10 μm) instead of thick paste applications, the process maintains high conductivity while minimizing the electrode thickness. This parameter optimization reduces sunlight blocking while preserving electrical performance.
Solution Approach 2:
The replacement of screen printing with PVD enables precise control of metal layer thickness at the micro-scale. The vapor deposition process creates uniformly thin metal lines that maintain conductivity without the excessive thickness required by paste methods, thereby reducing optical blocking while meeting electrical requirements.
3Ease of manufacture
If silver paste screen printing is used, then electrode manufacturing is achieved, but equipment complexity and process requirements increase for thin film solar cells
Solution Approach 1:
The patent replaces complex mechanical screen printing equipment with a PVD deposition system. The PVD process uses vacuum technology and controlled vapor deposition to create electrodes directly on the substrate, eliminating the need for complex printing machinery. This substitution simplifies the overall manufacturing equipment requirements while maintaining electrode fabrication capability.
Solution Approach 2:
The patent uses a mask pattern (stencil) to define the electrode geometry, copying the desired pattern onto the substrate through PVD deposition. This masking approach simplifies the process by using a simple template rather than complex printing mechanisms, making the system more adaptable to different electrode designs without requiring specialized equipment.
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 method significantly reduces production costs and sunlight shading while maintaining high efficiency by using a laser-etched polymer film mask for precise electrode formation.
Implementation Method 1
A mask is prepared by laser etching a polymer film according to a desired shape of an electrode
Implementation Method 2
a metal film is coated on the mask by a physical vapor deposition method so as to grow a metal electrode or an electrode seed layer with the desired shape on the substrate
Data Source
AI summary
Provided are a solar cell metal electrode and a preparation method therefor, and a mask. The preparation method for a solar cell metal electrode in the present invention comprises: laser-etching a polymer film according to a desired electrode shape to prepare a mask; and fixing the mask onto a substrate, and plating the mask with a metal film by using a physical vapor deposition method, so that a metal electrode or an electrode seed layer in the desired shape grows on the substrate. According to the method of the present invention, the preparation cost is low, the conductivity of an electrode prepared is high, the light shielding area is small, and the photoelectric conversion rate is high.