Solar Cell Scribing Sequence for Stronger Conductive Bonding

Solution Overview

Problem

The existing methods for manufacturing solar cells face challenges in improving quality, reducing manufacturing time, and lowering costs, particularly in the integration of wafer and thin film type solar cells.

Innovation Solution

A method that includes a mounting process for forming thin film layers, a print process for applying conductive material, and a scribing process using laser irradiation to divide the cell into units, with the option to perform these processes simultaneously or in a specific sequence to enhance bonding and reduce cracking, while also optimizing the cutting and bonding processes to decrease overall manufacturing time and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the scribing process is performed before the print process, then the cell can be divided into unit cells, but the bonding force of conductive material decreases and cracks may occur

Engineering Contradiction:

Improvecell division precisionVSAvoidbonding force of conductive material

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent applies preliminary action by performing the print process before the scribing process. The conductive material is printed onto the cell surface first, creating a protective and bonding layer before the laser scribing divides the cell. This sequence ensures that the conductive material is already in place to provide bonding strength and prevent cracks during the subsequent cutting operation, resolving the contradiction between cell division precision and bonding strength.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If multiple cutting processes are performed to divide the cell into multiple unit cells, then the cell can be divided into desired number of units, but the manufacturing time increases

Engineering Contradiction:

Improvecell division into multiple unitsVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by performing the print process before the scribing process. The conductive material is printed onto the cell surface first, creating a protective and bonding layer before the laser scribing divides the cell. This sequence ensures that the conductive material is already in place to provide bonding strength and prevent cracks during the subsequent cutting operation, resolving the contradiction between cell division precision and bonding strength.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the scribing and cutting processes into a single integrated laser processing step. The laser scribing simultaneously creates the division lines and performs the cutting function, eliminating the need for separate cutting operations. This consolidation reduces manufacturing time while maintaining the ability to divide cells into multiple unit cells with precise control.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If conventional manufacturing methods are used, then the process is simple, but the manufacturing cost and time are high

Engineering Contradiction:

Improveprocess simplicityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges the scribing and cutting processes into a single integrated laser processing step. The laser scribing simultaneously creates the division lines and performs the cutting function, eliminating the need for separate cutting operations. This consolidation reduces manufacturing time while maintaining the ability to divide cells into multiple unit cells with precise control.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent implements continuous useful action by performing the print process before scribing, ensuring that the conductive material is continuously applied and bonded during the entire cell division process. The laser scribing continuously moves across the cell surface, simultaneously scribing and cutting without interruption. This continuous operation eliminates idle time between processes and maintains high productivity throughout manufacturing.

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 enhances the bonding force of the conductive material, reduces the likelihood of cracks in the solar cells, decreases manufacturing time, and lowers the cost of facilities and production, thereby improving the quality and productivity of solar cells.

Implementation Method 1

a scribing process of irradiating a laser toward the cell to form a cell division part for dividing the cell into a plurality of unit cells

Methodology Applied

Scientific EffectLaser irradiation: Laser

Implementation Method 2

a scribing process of irradiating a laser toward the cell to form a cell division part for dividing the cell into a plurality of unit cells

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12255262B2Method for manufacturing solar cell

Publication Date: 2025.03.18 JUSUNG ENG

AI summary

The present invention relates to a method for manufacturing a solar cell, comprising: a seating process of seating, in a processing space for manufacturing a solar cell, a cell in which a plurality of thin film layers are formed; a coating process of spraying a conductive material onto the cell; and a scribing process of irradiating a laser toward the cell to form a cell separation unit for separating the cell into a plurality of unit cells.