Solar Cell Surface Roughness Layout for Passivation and Optical Loss
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Solution Overview
Problem
The photoelectric conversion efficiency of existing solar cells is poor due to surface defects and optical losses, which limits their effectiveness in converting sunlight into electrical energy.
Innovation Solution
A solar cell design featuring alternating electrode and non-electrode regions with distinct surface roughness, where the electrode regions have a flat surface and lower roughness than the non-electrode regions, incorporating a first tunneling dielectric layer, a doped conductive layer, and spot electrodes that penetrate the passivation layer to reduce surface defects and optical losses, while using different materials for the connecting and spot electrodes to minimize damage and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the surface of electrode regions is made rough to increase light absorption, then optical loss is reduced, but the deposition quality of tunneling dielectric layer and doped conductive layer deteriorates
Solution Approach 1:
The patent applies local quality by creating different surface roughness in different regions: the electrode regions have a first surface with lower roughness for high-quality deposition of tunneling dielectric and doped conductive layers, while the non-electrode regions have a second surface with higher roughness for enhanced light absorption. This spatial differentiation resolves the contradiction by allowing each region to have the surface characteristics needed for its specific function.
2Ease of manufacture
If traditional electrode structures are used, then manufacturing is simpler, but photoelectric conversion efficiency remains poor due to surface defects and optical losses
Solution Approach 1:
The patent segments the electrode structure into multiple components: tunneling dielectric layer, doped conductive layer, and passivation layer, each performing a specific function. The electrode regions and non-electrode regions are also segmented with different surface properties. This segmentation allows optimization of each component for its specific function while maintaining overall manufacturing feasibility.
Solution Approach 2:
Different regions are given different surface qualities: electrode regions have smooth surfaces for good electrical contact and layer deposition, while non-electrode regions have rough surfaces for enhanced light trapping. This local differentiation improves photoelectric conversion efficiency without making the manufacturing process overly complex.
3Ease of manufacture
If uniform surface roughness is applied across all regions, then manufacturing is easier, but both light absorption and deposition quality cannot be optimized simultaneously
Solution Approach 1:
The patent implements local quality by specifying that the first surface (electrode regions) has a first roughness value optimized for deposition, while the second surface (non-electrode regions) has a second roughness value optimized for light absorption. This allows each region to have the surface characteristics needed for its specific function while using standard manufacturing processes to achieve the differentiation.
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 design enhances the passivation effect, reduces surface defects, and improves the photoelectric conversion efficiency by optimizing the deposition and sintering processes, leading to better light utilization and reduced material usage.
Implementation Method 1
a first tunneling dielectric layer having portions formed over the electrode regions, respectively, a first doped conductive layer formed over the first tunneling dielectric layer
Implementation Method 2
a passivation layer formed over the non-electrode regions and the first doped conductive layer
Implementation Method 3
The multiple spot electrodes penetrate the passivation layer to be in contact with the first doped conductive layer
Implementation Method 4
A solar cell is a device that converts the light energy of the sun into electrical energy. The solar cell uses the principle of photovoltaics to generate carriers
Data Source
AI summary
The solar cell includes a substrate having electrode regions and non-electrode regions alternatingly. The electrode regions have a first surface, the non-electrode regions have a second surface, and the first surface has a smaller roughness than the second surface. The solar cell further includes a first tunneling dielectric layer formed over the first surface, a first doped conductive layer arranged on a side of the first tunneling dielectric layer, a passivation layer formed over the second surface and the first doped conductive layer, and at least one first electrode. The at least one first electrode are arranged in the electrode regions, each of the at least one first electrode includes a connecting electrode formed over the electrode regions and multiple spot electrodes. The multiple spot electrodes are arranged below the connecting electrode and connected to the connecting electrode.