Stacked Solar Cell Electrode Structure to Prevent Sharp Wedge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar cells are prone to the sharp wedge phenomenon during sintering of metal paste electrodes, leading to increased manufacturing costs due to the high cost of metal paste required for ensuring electrical properties.
Innovation Solution
A solar cell design featuring a stacked structure with a semiconductor transport layer between conductive layers, reducing direct contact and penetration into the substrate, thereby minimizing the sharp wedge effect and using lower-cost materials for reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal paste is used for electrodes to ensure electrical properties, then electrical conductivity is improved, but manufacturing cost increases and sharp wedge phenomenon occurs
Solution Approach 1:
The electrode is segmented into multiple functional layers: a lower-cost base conductive layer provides bulk conductivity, while a thinner upper transport layer optimizes electrical properties and reduces metal paste consumption. This segmentation allows each layer to perform its specific function efficiently, reducing overall material cost while maintaining electrical performance.
Solution Approach 2:
The patent optimizes the thickness and material composition parameters of each electrode layer. By carefully controlling the thickness of the transport layer (1-10 μm) and base conductive layer (10-100 μm), and selecting appropriate material compositions, the electrode achieves required electrical conductivity with minimized metal paste usage, thereby reducing manufacturing cost.
2Reliability
If metal paste is used for electrodes to ensure electrical properties, then electrical conductivity is improved, but sharp wedge phenomenon occurs during sintering
Solution Approach 1:
The patent introduces an intermediate transport layer between the substrate and the base conductive layer. This transport layer acts as a mediator that facilitates electrical connection while preventing the sharp wedge phenomenon. The transport layer's specific material properties and thickness (1-10 μm) enable it to buffer the thermal and mechanical stresses during sintering, preventing metal paste from penetrating into the substrate and forming sharp wedges.
Solution Approach 2:
The electrode uses a composite structure combining different materials with complementary properties. The transport layer is made from materials with appropriate melting points and reactivity characteristics that prevent harmful interactions with the substrate during sintering, while the base conductive layer provides bulk conductivity. This composite approach eliminates the sharp wedge phenomenon while maintaining electrical performance.
3Reliability
If thicker metal paste layer is used to ensure electrical properties, then electrical conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The electrode is segmented into multiple functional layers: a lower-cost base conductive layer provides bulk conductivity, while a thinner upper transport layer optimizes electrical properties and reduces metal paste consumption. This segmentation allows each layer to perform its specific function efficiently, reducing overall material cost while maintaining electrical performance.
Solution Approach 2:
The patent optimizes the thickness and material composition parameters of each electrode layer. By carefully controlling the thickness of the transport layer (1-10 μm) and base conductive layer (10-100 μm), and selecting appropriate material compositions, the electrode achieves required electrical conductivity with minimized metal paste usage, thereby reducing manufacturing cost.
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 design enhances electrical properties while reducing recombination loss and improving short-circuit voltage and cell efficiency, while also lowering manufacturing costs by minimizing the use of high-cost metal pastes.
Implementation Method 1
the first transport layer is made of a semiconductor material and configured to electrically connect the first conductive layer with the second conductive layer
Implementation Method 2
the first conductive layer is sintered by a silver-aluminum paste, and the second conductive layer is sintered by an aluminum paste or a silver-aluminum paste
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A solar cell and a photovoltaic module, including a substrate and a first electrode. The first electrode is arranged on a surface of the substrate and electrically connected to the substrate. Along a thickness direction of the substrate, the first electrode is provided with a first conductive layer, a second conductive layer, and a first transport layer. The first transport layer is located between the first conductive layer and the second conductive layer, and the first transport layer is made of a semiconductor material and configured to electrically connect the first conductive layer with the second conductive layer.