Solar Cell Electrode Plating With Seed Layers and Horizontal Transport
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Solution Overview
Problem
The existing electrode manufacturing method for solar cells faces challenges in achieving an optimal electrode width, as larger widths improve efficiency but are limited by laser film perforation damage, and smaller widths lead to finger fall-off and increased line resistance, while vertical electroplating methods are inefficient for scale production and affect conversion efficiency.
Innovation Solution
A method involving film layer perforation and growth of a seed layer on solar cells, allowing for horizontal electroplating with a cathode brush contact, which increases electrode width, reduces line resistance, and enables efficient scale production by overcoming the limitations of vertical electroplating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the film perforation size by laser is increased to achieve larger electrode width, then the line resistance of the solar cell is reduced, but the laser damage becomes more serious
Solution Approach 1:
The invention divides the electrode structure into multiple components: a metal layer deposited by screen printing and an electroplated layer formed through electroplating process. This segmentation allows the metal layer to provide initial conductivity and structural support, while the electroplated layer enhances conductivity without requiring excessive laser perforation, thus reducing laser damage while maintaining low line resistance
Solution Approach 2:
The metal layer is deposited on the solar cell surface before the electroplating process. This preliminary action creates a conductive base layer that facilitates subsequent electroplating and provides initial electrical connectivity, allowing the electroplated layer to form with smaller perforation sizes, thereby reducing laser damage while achieving low line resistance
2Length of moving object
If the electrode width is increased to reduce line resistance, then the conversion efficiency is improved, but the finger may fall off more easily
Solution Approach 1:
The invention creates a composite electrode structure consisting of a metal layer (deposited by screen printing) and an electroplated layer (formed through electroplating). This composite structure combines the adhesion properties of the metal layer with the high conductivity of the electroplated layer, ensuring strong finger adhesion while maintaining low line resistance through the conductive electroplated layer
3Ease of manufacture
If the vertical electroplating method is used to manufacture electrodes, then the process is simple, but the electroplating efficiency is low and it is difficult to satisfy scale production requirements
Solution Approach 1:
The invention inverts the traditional vertical electroplating approach by implementing horizontal electroplating. In this method, the solar cell moves horizontally through the electroplating bath while the cathode and anode are positioned horizontally, enabling streamlined processing and continuous production, thus dramatically improving electroplating efficiency and satisfying scale production requirements while maintaining manufacturing simplicity
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 allows for a wider electrode width, reducing line resistance and preventing finger fall-off, while enabling streamlined horizontal electroplating that addresses the inefficiencies of vertical electroplating, thereby enhancing solar cell efficiency and supporting large-scale production.
Implementation Method 1
a cathode electroplating brush is in contact with the seed layer on the horizontally transmitted solar cell, to form a cathode of an electroplating system on the seed layer
Implementation Method 2
an anode terminal is disposed in an electroplating liquid in an electroplating bath
Implementation Method 3
a moving mechanism disposed in the electroplating bath drives the solar cell to move from an inlet to an outlet of the moving mechanism of the solar cell, thus achieving electroplating of the solar cell during energization and the horizontal transmission
Data Source
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AI summary
The disclosure discloses a method for manufacturing a solar cell, a solar module, and a power generation system. The manufacturing method includes the following steps: S1: perforating film layer in a first region (100) and/or a second region (200) of a solar cell where an electrode is to be disposed, thus forming a plurality holes (2); S2: growing a plurality seed layers (1) on the solar cell, contacting with the first region and/or the second region through the plurality of holes or grooves in S1; and S3: horizontally transporting a to-be-electroplated solar cell on a horizontal electroplating device, to form a cathode on the seed layer, where an anode terminal is disposed in an electroplating liquid in an electroplating bath, and a moving mechanism disposed in the electroplating bath drives the solar cell to move from inlet to outlet, thus achieving electroplating.