Solar Cell Electrode Aspect Ratio via Stencil Printing
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Solution Overview
Problem
Existing solar cell manufacturing techniques face challenges in achieving high aspect ratios for electrodes, which are crucial for enhancing photoelectric conversion efficiency, as they often result in electrodes with insufficient fineness and light conversion efficiency.
Innovation Solution
A method involving stencil printing of a conductive paste comprising 60-95 wt% conductive powder, 0.1-10 wt% glass frit, 3-30 wt% organic medium, and 0.4-1.7 wt% amide compound onto a semiconductor substrate, followed by firing, to form solar cell electrodes with improved aspect ratios and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional screen-printing techniques are used to form solar cell electrodes, then the manufacturing process is simple and easy to implement, but the electrode aspect ratio is insufficient and photoelectric conversion efficiency is low
Solution Approach 1:
The patent changes the printing parameters by specifying precise conductive paste composition ratios (silver powder 60-95 wt%, glass frit 0.1-10 wt%, organic medium 3-30 wt%, amide compound 0.4-1.7 wt%) and printing conditions to achieve high aspect ratio electrodes (0.5-1.5) that conventional screen-printing cannot accomplish
Solution Approach 2:
The patent introduces an amide compound as an intermediary substance in the conductive paste formulation. This amide compound acts as a binder and flow control agent that enables the paste to maintain its shape during drying, achieving high aspect ratio electrodes with fine line widths that would otherwise collapse in conventional printing processes
2Manufacturing precision
If electrode line width is reduced to improve fineness, then photoelectric conversion efficiency increases, but electrode strength and conductivity decrease
Solution Approach 1:
The patent creates a composite conductive paste material combining silver powder (60-95 wt%), glass frit (0.1-10 wt%), organic medium (3-30 wt%), and amide compound (0.4-1.7 wt%). This composite formulation maintains electrode strength and conductivity even at reduced line widths by providing structural support through the glass frit and binding properties of the amide compound
Solution Approach 2:
The patent optimizes the composition parameters of the conductive paste, specifically adjusting the ratio of silver powder to glass frit and organic medium, to enable formation of ultra-fine electrodes (line width 5-50 μm) that maintain adequate mechanical strength and electrical conductivity for solar cell operation
3Manufacturing precision
If conductive paste composition is optimized for high aspect ratio, then photoelectric conversion efficiency improves, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the conductive paste composition parameters to use silver powder at 60-95 wt% (lower than conventional 80-99 wt%), replacing some expensive silver with glass frit and organic medium while maintaining electrode performance through the amide compound binder system, thereby reducing material cost while achieving high aspect ratio electrodes
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 method effectively enhances the aspect ratio and photoelectric conversion efficiency of solar cell electrodes, achieving high light conversion efficiency by forming electrodes with a high aspect ratio and excellent fineness.
Implementation Method 1
firing the applied conductive paste to form an electrode
Data Source
AI summary
A method of manufacturing a solar electrode comprising steps of:(a) stencil printing a conductive paste onto a front side of a semiconductor substrate through a printing mask comprising: (i) 60 wt % to 95 wt % of a conductive powder, (ii) 0.1 wt % to 10 wt % of glass frit, (iii) 3 wt % to 30 wt % of an organic medium, (iv) 0.4 wt % to 1.7 wt % of an amide compound, based on the total weight of the conductive paste and (b) firing the applied conductive paste to form an electrode.