Solar Cell Electrode Structure With Seed Layer Diffusion Barrier
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Solution Overview
Problem
The existing structure of solar cells suffers from reduced photoelectric efficiency due to material diffusion between the conductive film and the substrate, and challenges in light reflection and adhesion, which affect the short circuit current and reliability of the cells.
Innovation Solution
A solar cell electrode structure featuring a seed layer with a specific alloy composition and a conductive metal layer forming a suspended structure, where the seed layer is thinner than the conductive layer, enhancing light reflection and preventing material diffusion, combined with a protective layer to improve adhesion and reduce oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive film layer is directly applied on the substrate, then electrical conductivity is achieved, but material molecules diffuse into the substrate forming a composite pair which reduces photoelectric efficiency
Solution Approach 1:
The patent introduces a seed layer as an intermediary between the conductive film layer and the substrate. This seed layer prevents direct contact and material diffusion between the conductive film and substrate, thereby eliminating the harmful composite pair formation while maintaining electrical conductivity. The seed layer acts as a barrier that mediates the interaction between the conductive film and substrate.
Solution Approach 2:
The patent segments the originally single-layer conductive film structure into multiple distinct layers: a seed layer and a conductive film layer. This segmentation separates the functions of adhesion/prevention (seed layer) and electrical conductivity (conductive film layer), allowing each layer to perform its specific function without causing material diffusion issues.
2Reliability
If a thick conductive film layer is used to ensure good electrical connection, then conductivity improves, but adhesion to the substrate deteriorates and oxidation risk increases
Solution Approach 1:
The patent segments the conductive film into a seed layer and a conductive film layer. The seed layer is designed with optimal thickness for strong adhesion to the substrate, while the conductive film layer provides the necessary electrical conductivity. This segmentation allows each layer to have optimal thickness for its specific function, preventing the adhesion deterioration that occurs with thick single-layer conductive films.
Solution Approach 2:
The seed layer acts as an intermediary between the substrate and the thick conductive film layer. It provides strong adhesion to the substrate and prevents direct interaction between the thick conductive film and substrate that would cause adhesion deterioration and oxidation. The seed layer mediates the interface, allowing the conductive film to be thick for conductivity without compromising adhesion.
3Ease of manufacture
If copper is used as the main conductive material to reduce cost, then manufacturing cost decreases, but material diffusion into the substrate increases reducing photoelectric efficiency
Solution Approach 1:
The patent introduces a seed layer as an intermediary between the copper-based conductive film and the substrate. This seed layer prevents copper atoms from diffusing into the substrate, thereby eliminating the harmful effect of copper diffusion on photoelectric efficiency while allowing the use of cost-effective copper as the main conductive material.
Solution Approach 2:
The patent creates a composite structure consisting of a seed layer and a copper-based conductive film layer. This composite material structure combines the low cost of copper with the protective function of the seed layer, achieving both cost reduction and prevention of material diffusion into the substrate.
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
The solution increases the photoelectric conversion efficiency, improves adhesion, and reduces the risk of electrode failure, while also offering a cost-effective alternative to silver by using copper and other metals, facilitating mass production.
Implementation Method 1
enhancing light reflection
Implementation Method 2
preventing material diffusion
Implementation Method 3
reduce oxidation
Data Source
AI summary
The present disclosure discloses an electrode structure of a solar cell, which belongs to the technical field of Photovoltaic (PV) cells and includes a conducting layer, and one end, configured to be connected to the solar cell, of the conducting layer is provided with a seed layer, and a width of the seed layer is less than that of the conducting layer. The present disclosure also discloses the solar cell, a cell module and a power generation system applying the electrode structure.