Pressure-Assisted Solar Cell Fabrication for Better Interfacial Contact

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Solution Overview

Problem

The fabrication of photovoltaic devices, such as solar cells and light emitting devices, is hindered by the presence of particles like silicone, silicon, and silica in clean room environments, which reduce the performance by creating voids and inhibiting effective contact between layers.

Innovation Solution

A method involving the application of pressure during the fabrication process to deform the active layer around interlayer particles, enhancing electrical contact between layers, and subsequent annealing to improve the efficiency and performance of photovoltaic devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pressure is applied to deform the active layer around particles, then electrical contact between layers is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improveelectrical contact between layersVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Pressure is applied during the fabrication process before final device completion, proactively removing particles and improving interfacial contact between layers. This preliminary action prevents contact issues from developing later, resolving the contradiction by establishing reliable electrical contact early in manufacturing without requiring complex post-processing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fabrication process utilizes controlled pressure application as a adjustable parameter to deform the active layer around particles, optimizing interfacial contact. By treating pressure as a controllable manufacturing parameter rather than a fixed condition, the process achieves improved electrical contact while maintaining manageable complexity through parameter optimization.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If pressure is applied to increase interfacial contact, then power conversion efficiency increases, but the risk of damaging the device structure increases

Engineering Contradiction:

Improvepower conversion efficiencyVSAvoidstructural integrity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

Pressure is applied at controlled levels during fabrication to achieve sufficient interfacial contact improvement without exceeding the structural tolerance of the device. This partial action approach optimizes efficiency gains while preventing damage, resolving the contradiction by applying just enough pressure to improve contact without compromising structural integrity.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The fabrication process incorporates pressure control measures and structural support mechanisms beforehand to cushion against potential damage during the pressure application step. This preparatory cushioning allows efficient contact improvement while protecting the device structure from excessive stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If pressure application and annealing are added to the fabrication process, then device performance is improved, but the manufacturing time increases

Engineering Contradiction:

Improvedevice performanceVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The pressure application step is integrated with the annealing process, combining two separate operations into a unified manufacturing step. This merging achieves both interfacial contact improvement and thermal processing benefits simultaneously, resolving the contradiction by improving device performance without proportionally increasing total manufacturing time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fabrication process maintains continuous useful action by seamlessly transitioning from pressure application to annealing without interrupting the manufacturing flow. This continuity ensures that both performance-improving steps occur in an integrated manner, minimizing idle time while achieving enhanced device performance.

Inventive Principle:

Principle #20Continuity of useful action

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 increases the power conversion efficiency of photovoltaic devices by up to 15% and reduces turn-on voltage, while maintaining structural integrity by optimizing interfacial contacts and reducing voids between layers.

Implementation Method 1

applying pressure deforms the active layer around one or more interlayer particles disposed between the active layer and the one or more interfacial layers

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

annealing the photovoltaic device

Methodology Applied

Scientific EffectAnnealing: Annealing

Data Source

PatentUS20230422590A1Pressure assisted fabrication of solar cells and light emitting devices

Publication Date: 2023.12.28 WORCESTER POLYTECHNIC INSTITUTE

AI summary

Methods and systems for fabricating photovoltaic devices are provided. A method includes forming a photovoltaic device comprising an active layer with one or more interfacial layers adjacent the active layer, wherein the active layer comprises a photovoltaic material and the one or more interfacial layers comprise a material configured to collect charge carriers generated in the photovoltaic material; applying pressure onto the photovoltaic device to increase an amount of electrical contact between the active layer and the one or more interfacial layer; and annealing the photovoltaic device.