Solar Cell Electrode Contact Improvement by Cross-Path Laser Sintering
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Solution Overview
Problem
The conversion efficiencies of existing solar cells need to be improved.
Innovation Solution
A method involving a metallization heat treatment process to form a first initial electrode on a solar cell substrate, followed by laser-assisted sintering treatment with controlled laser irradiation, where the laser's moving direction intersects with the electrode's longitudinal extension direction to enhance contact performance between the electrode and substrate, exciting carriers in non-electrode regions to generate local currents, promoting mutual fusion and diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metallization heat treatment process is used to form electrode, then manufacturing process is simple, but contact performance between electrode and substrate is insufficient
Solution Approach 1:
The patent combines metallization heat treatment process with laser-assisted sintering treatment into a unified manufacturing process. The laser treatment is applied to the electrode formed by conventional metallization, merging two processes to achieve both simple manufacturing and improved contact performance simultaneously.
Solution Approach 2:
The patent applies laser irradiation with specific parameters (continuous moving irradiation, controlled power, specific moving direction intersecting with electrode longitudinal extension direction) to change the physical state of the electrode-substrate interface, improving contact performance through controlled thermal and mechanical effects.
2Reliability
If laser irradiation is applied to enhance electrode contact performance, then conversion efficiency improves, but energy consumption increases
Solution Approach 1:
The laser irradiation is applied locally to specific regions of the electrode-substrate interface rather than uniformly across the entire solar cell. The continuous moving irradiation targets areas where contact performance needs improvement, concentrating energy where needed and reducing overall energy consumption.
Solution Approach 2:
The patent uses continuous moving irradiation instead of intermittent or stationary laser treatment. This continuous action ensures uniform and consistent heating across the electrode region, improving contact performance efficiently while minimizing total energy consumption by avoiding repeated heating cycles.
3Reliability
If laser moving direction is parallel to electrode longitudinal extension direction, then processing is simple, but carrier excitation in non-electrode regions is insufficient
Solution Approach 1:
The patent intentionally sets the laser moving direction to intersect with the electrode longitudinal extension direction at a specific angle, creating an asymmetric irradiation pattern. This asymmetric approach enables effective carrier excitation in non-electrode regions while maintaining reasonable laser control complexity through defined geometric relationships.
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 method improves the contact performance between the electrode and substrate, enhancing the conversion efficiency of the solar cell while simplifying the manufacturing process and increasing efficiency.
Implementation Method 1
controlling a laser to perform a continuous moving irradiation on the solar cell substrate and performing a laser-assisted sintering treatment on the first initial electrode
Implementation Method 2
performing a laser-assisted sintering treatment on the first initial electrode to form a first electrode
Implementation Method 3
exciting carriers in non-electrode regions to generate local currents
Implementation Method 4
forming, by a metallization heat treatment process, a first initial electrode on the solar cell substrate
Data Source
AI summary
Disclosed is a method for manufacturing solar cell. The method includes: providing a solar cell substrate; forming a first initial electrode on the solar cell substrate; and controlling a laser to perform a continuous moving irradiation on the solar cell substrate, and performing a laser-assisted sintering treatment on the first initial electrode to form a first electrode and obtain the solar cell. The number of times the laser is controlled to perform the continuous moving irradiation on the solar cell substrate is at least once. There is a target irradiation process among all continuous moving irradiation processes, in which a moving direction of the laser and a longitudinal extension direction of the first electrode intersect with each other and are perpendicular to a thickness direction of the solar cell substrate.