Solar Cell Texturization Homogeneity via Pre-Cleaning
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Solution Overview
Problem
Current solar cell texturization processes often result in inhomogeneous morphology due to inadequate removal of contaminants and physical damage from the sawing process, leading to non-uniform reflectance and light absorption.
Innovation Solution
A pre-cleaning step using ozonated deionized water or aqueous solutions of potassium hydroxide or sodium hydroxide is applied to the as-cut crystalline silicon substrates to remove surface contaminants, followed by a saw damage removal step and then texturization, ensuring a uniform textural morphology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If texturization is performed directly on as-cut surfaces, then the texturization process is simpler and faster, but the textural morphology becomes inhomogeneous due to contaminants and saw damage
Solution Approach 1:
The patent applies pre-cleaning and saw damage removal steps before texturization to prepare the substrate surface. This preliminary action removes contaminants and physical damage that would otherwise cause inhomogeneous textural morphology, ensuring uniform light absorption while maintaining a manageable texturization process
Solution Approach 2:
The texturization process is divided into distinct sequential steps: pre-cleaning, saw damage removal, and texturization. This segmentation allows each step to be optimized independently, with pre-cleaning removing organic/inorganic contaminants and saw damage removal addressing mechanical damage, resulting in superior textural uniformity
2Manufacturing precision
If pre-cleaning and saw damage removal steps are added, then textural morphology uniformity is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
By performing pre-cleaning and saw damage removal before texturization, the patent ensures that the texturization step operates on a uniformly prepared surface, reducing the need for rework or additional correction steps that would increase total processing time
Solution Approach 2:
The patent optimizes the chemical parameters of cleaning and etching solutions, as well as their application conditions (temperature, concentration, contact time), to achieve effective surface preparation in minimal time while maintaining textural morphology uniformity
3Use of energy by moving object
If contaminants and saw damage are not removed, then the manufacturing process is simpler, but light absorption is reduced due to non-uniform reflectance
Solution Approach 1:
The pre-cleaning and saw damage removal steps create a uniformly prepared surface that enables consistent light absorption across the entire substrate. This preliminary preparation ensures that the texturized surface has homogeneous reflectance properties, maximizing solar energy capture efficiency
Solution Approach 2:
The patent applies different treatment conditions to address local surface issues: pre-cleaning removes contaminants uniformly across the surface, while saw damage removal specifically targets mechanically damaged regions, creating a locally optimized surface that uniformly absorbs light after texturization
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 pre-cleaning step significantly improves the homogeneity of textural structures, reducing surface reflectance and enhancing light absorption, leading to more efficient solar cell performance.
Implementation Method 1
applying ozonated deionized water to an as-cut surface of a crystalline silicon substrate to remove surface contaminants
Implementation Method 2
applying ozonated deionized water to an as-cut surface of a crystalline silicon substrate
Implementation Method 3
applying a first etching solution to the pre-cleaned surface to remove physical damage caused during the sawing process
Implementation Method 4
applying a second etching solution to the prepared surface to texturize the prepared surface
Implementation Method 5
applying a first aqueous solution of potassium hydroxide or sodium hydroxide to an as-cut surface of a crystalline silicon substrate to remove surface contaminants
Implementation Method 6
applying an alkaline solution to the prepared surface to texturize the prepared surface
Data Source
AI summary
A method of manufacturing a solar cell wherein a pre-cleaning step is completed prior to a saw damage removal step and prior to texturization, thereby resulting in the subsequently formed textured surface to have a more homogeneous textural morphology. In one aspect, the invention is a method comprising: a) applying a pre-cleaning solution to an as-cut surface of a crystalline silicon substrate to remove surface contaminants, thereby converting the as-cut surface to a pre-cleaned surface, the as-cut surface formed by a sawing process to create the crystalline silicon substrate; b) applying a first etching solution to the pre-cleaned surface to remove physical damage caused during the sawing process, thereby converting the pre-cleaned surface into a prepared surface; c) applying a second etching solution to the prepared surface to texturize the prepared surface, thereby converting the prepared surface into a texturized surface; and d) forming at least one solar cell on the texturized surface of the crystalline silicon substrate.