Solar Cell Module Carrier Vias for Thin Epitaxial Silicon Handling
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Solution Overview
Problem
Thin epitaxial silicon solar cells are difficult to handle and connect electrically, especially during metallization, which complicates the formation of solar cell modules.
Innovation Solution
A carrier is attached to the backside of the solar cell, with vias formed through it to facilitate electrical connections between cells, allowing for serial connection without the need for de-bonding the carrier, and metal connections are made through these vias to connect adjacent cells in a solar cell module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thin epitaxial silicon solar cells are used to improve efficiency and reduce material cost, then productivity and cost-effectiveness are improved, but handling difficulty and electrical connection complexity increase
Solution Approach 1:
A carrier substrate is introduced as an intermediary element to support thin epitaxial silicon solar cells during handling and electrical connection processes. The carrier provides mechanical support and facilitates metallization operations, solving the handling difficulty inherent in thin solar cells while maintaining productivity benefits
2Reliability
If traditional metallization methods are used for electrical connection, then manufacturing simplicity is maintained, but connection reliability and process complexity increase for thin cells
Solution Approach 1:
The carrier substrate is prepared in advance with metallization layers and connection structures before the thin solar cells are attached. This preliminary action enables reliable electrical connections to be made through the carrier, avoiding the need to directly metallize fragile thin cells and reducing overall process complexity
3Ease of operation
If carriers are attached to solar cells to facilitate handling and connection, then handling ease and connection reliability are improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The carrier substrate is merged with multiple solar cells to form an integrated assembly unit. This combining approach allows the carrier to serve multiple functions simultaneously: mechanical support, electrical connection facilitation, and module assembly guidance, thereby reducing overall system complexity despite adding a component
Data Source
AI summary
A solar cell module includes serially connected solar cells. A solar cell includes a carrier that is attached to the backside of the solar cell. Solar cells are attached to a top cover, and vias are formed through the carriers of the solar cells. A solar cell is electrically connected to an adjacent solar cell in the solar cell module with metal connections in the vias.