Solar Cell Precursor Electroplating with Flexible Conductive Pieces
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Solution Overview
Problem
Existing methods for electroplating solar cell precursors face challenges such as cracking, scratching, and non-uniformity due to the use of hard conductors and rollers, which affect the appearance and efficiency of solar cells, particularly for structures requiring metal grid lines on both surfaces.
Innovation Solution
A method using flexible conductive pieces that are attached to mask openings on the solar cell precursor, forming electrical connections without hard clamping, and are easily detachable after electroplating, allowing for uniform deposition of metal on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard conductors or rollers are used to clamp solar cell precursors for electroplating, then electrical connection is achieved, but cracking and scratching occur on the precursor surface
Solution Approach 1:
The patent employs flexible conductive pieces made of soft material that can conform to the precursor surface without applying hard clamping force. These flexible pieces establish electrical connection through contact with the conductive adhesive layer, avoiding the mechanical stress that causes cracking and scratching while maintaining reliable electrical connection for electroplating.
Solution Approach 2:
The patent introduces a conductive adhesive layer as an intermediary between the flexible conductive piece and the precursor surface. This adhesive layer provides both electrical conductivity and soft contact, mediating the interaction to ensure reliable electrical connection while preventing direct hard contact that would damage the precursor surface.
2Productivity
If rollers are used as cathode material for electroplating, then electroplating can be performed, but regular deplating treatment is required which causes downtime
Solution Approach 1:
The patent uses disposable flexible conductive pieces that are discarded after a single use, eliminating the need for deplating treatment. These cheap, single-use pieces are attached to the precursor, used for electroplating, and then removed without causing contamination or requiring cleaning cycles, thereby eliminating downtime and improving productivity.
Solution Approach 2:
The patent implements a strategy of discarding the flexible conductive piece after use rather than recovering and reusing it. The piece is attached to the precursor for electroplating, then easily removed and discarded, avoiding the time-consuming deplating process required for reusable rollers and maximizing production efficiency.
3Reliability
If conductive brush is used to contact solar cell precursor surface, then electrical connection is provided, but the brush scratches the surface and requires pre-deposition of metal layer
Solution Approach 1:
The patent replaces the rigid conductive brush with flexible conductive pieces made of soft material. These flexible pieces contact the precursor surface gently without scratching, while the conductive adhesive layer ensures reliable electrical connection. This eliminates the need for pre-deposition of metal layers that would be required if a conductive brush were used.
4Object-affected harmful factors
If ionic liquid is used as conductive medium to avoid hard contact, then surface damage is reduced, but local primary battery formation causes corrosion and non-uniform electroplating
Solution Approach 1:
The patent uses a conductive adhesive layer as an intermediary between the flexible conductive piece and the precursor surface. This adhesive layer provides electrical conductivity without requiring ionic liquid, preventing the formation of local primary batteries that cause corrosion. It ensures uniform current distribution across the contact area, enabling non-uniform electroplating while avoiding the harmful effects of ionic liquid contact.
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 avoids cracking and improves electroplating uniformity, enhances production efficiency by eliminating the need for deplating conductive pieces, and ensures reliable electrical performance.
Implementation Method 1
a method for electroplating a solar cell precursor
Data Source
AI summary
Disclosed are a method and apparatus for electroplating a solar cell precursor. The method includes providing a mask opening on a surface of a cell precursor to be electroplated, such that a conductive material layer of the cell precursor is exposed at a bottom of the mask opening. The method further includes directly or indirectly connecting a first end portion of a conductive piece to the conductive material layer of the cell precursor, such that an electrical connection is formed between the conductive piece and the cell precursor. The conductive piece is a flexible structure capable of being bent.