Dual-Layer Solar Cell Passivation for Efficiency and Forming Speed
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Solution Overview
Problem
The existing passivation layers in solar cells do not effectively enhance photoelectric conversion efficiency due to inconsistent material properties and forming processes, leading to suboptimal passivation effects.
Innovation Solution
A solar cell design featuring a first passivation layer with a higher atomic packing density and thinner average thickness, formed using atomic layer deposition, paired with a second passivation layer of lower atomic packing density and thicker average thickness, formed using plasma-enhanced chemical vapor deposition, to improve both passivation effect and forming efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single passivation layer is formed to improve photoelectric conversion efficiency, then the passivation effect is enhanced, but the forming efficiency and manufacturing complexity increase
Solution Approach 1:
The passivation layer is divided into two separate layers: a first passivation layer formed by ALD with high atomic packing density for optimal passivation effect, and a second passivation layer formed by PECVD with lower atomic packing density for faster formation. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between passivation quality and forming efficiency.
Solution Approach 2:
The invention changes the formation parameters of the passivation layer by using two different deposition methods (ALD and PECVD) with different atomic packing densities. The first layer uses ALD parameters for high density and quality, while the second layer uses PECVD parameters for faster deposition, thereby optimizing both passivation effect and forming efficiency.
2Reliability
If the passivation layer thickness is increased to improve passivation quality, then the photoelectric conversion efficiency improves, but the manufacturing precision and uniformity decrease
Solution Approach 1:
By segmenting the passivation layer into two layers with different thicknesses and formation methods, the invention achieves high passivation quality through the first thin ALD layer while the second PECVD layer provides additional protection. The ALD process inherently provides better thickness uniformity for the critical first layer.
Solution Approach 2:
The first passivation layer near the substrate interface is formed with high atomic packing density using ALD to provide superior local passivation quality where it is most needed, while the second layer provides additional coverage. This local optimization of quality resolves the contradiction between overall passivation quality and manufacturing precision.
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 configuration enhances the photoelectric conversion efficiency of solar cells by optimizing the passivation layers' material properties and forming processes, balancing passivation effect and forming efficiency while ensuring reliability and reduced wraparound issues.
Implementation Method 1
formed using atomic layer deposition (ALD) and plasma-enhanced chemical vapor deposition (PECVD) to optimize film quality and coverage
Implementation Method 2
formed using atomic layer deposition (ALD) and plasma-enhanced chemical vapor deposition (PECVD) to optimize film quality and coverage
Implementation Method 3
The dual-layer structure enhances the passivation effect while maintaining high forming efficiency, reducing recombination rates and improving overall photoelectric conversion efficiency of solar cells
Implementation Method 4
improving overall photoelectric conversion efficiency of solar cells
Data Source
AI summary
The present application relates a solar cell, a photovoltaic device and a photovoltaic system. The solar cell includes a substrate, a first passivation layer, and a second passivation layer. The substrate includes a first surface and a second surface opposite to each other along a thickness direction of the substrate. The first passivation layer is disposed on the first surface of the substrate. The second passivation layer is disposed on a side of the first passivation layer away from the substrate. A material of the first passivation layer is the same as that of the second passivation layer. An atomic packing density of the first passivation layer is higher than that of the second passivation layer. An average thickness of the first passivation layer is smaller than that of the second passivation layer.