Adaptive Solar Cell Front Wiring Around Surface Inconsistencies

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Solution Overview

Problem

Inconsistencies on semiconductor substrates used in solar cells can lead to shorting and increased resistance in the front wiring, degrading the performance of solar cells due to the overlap of metal wiring with surface irregularities, which existing fabrication methods fail to effectively address.

Innovation Solution

A method that involves detecting inconsistencies on the semiconductor substrate and determining a deposition pattern to avoid these irregularities, allowing for selective deposition of conductive lines that circumvent or are separated from them by insulating layers, thereby reducing the risk of shorting and resistance issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fabrication methods are used to form front wiring on solar cells, then the wiring can be formed efficiently, but the metal wiring may overlap with inconsistencies in the semiconductor layers causing shorting and increased resistance

Engineering Contradiction:

Improvewiring performanceVSAvoidfabrication process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by detecting inconsistencies in the semiconductor substrate before forming the front wiring. The system scans the substrate surface, identifies defects such as particles or no-growth regions, and uses this information to guide subsequent wiring formation, preventing wiring from overlapping with inconsistent areas.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements dynamics by making the wiring formation process adaptive rather than static. The front wiring pattern is dynamically adjusted based on real-time detection of substrate inconsistencies, allowing the wiring layout to be customized for each substrate while maintaining efficient current collection.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the wiring pattern is fixed using conventional photolithography, then mass production is efficient, but the wiring cannot be tailored to avoid specific inconsistencies in individual substrates

Engineering Contradiction:

Improvewiring pattern adaptabilityVSAvoidfabrication speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system transitions from static fixed wiring patterns to dynamic adaptive patterns. Each substrate is scanned for inconsistencies, and the wiring pattern is dynamically generated and deposited accordingly, enabling customization without sacrificing production efficiency through automated real-time pattern generation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements feedback by using detection information from substrate scanning to guide the wiring formation process. The system continuously monitors substrate quality and adjusts the wiring deposition pattern based on this feedback, ensuring wiring avoids inconsistent areas while maintaining production throughput.

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If metal wiring is deposited directly on inconsistent areas, then the fabrication process is simple, but the resistance and shorting risk of the wiring increases

Engineering Contradiction:

Improvewiring fabrication simplicityVSAvoidwiring placement precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The system performs preliminary detection and mapping of inconsistent areas before wiring deposition. This preliminary action enables precise wiring placement that avoids defects while maintaining fabrication simplicity through automated guidance, eliminating the need for manual inspection and adjustment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual or fixed mechanical wiring deposition with an automated system that uses detection data to guide metal deposition. This substitution maintains ease of manufacture through automation while achieving high manufacturing precision by dynamically adjusting deposition patterns based on real-time substrate characterization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 improves current gathering and increases the output power of solar cells by tailoring the wiring to avoid surface defects, enhancing device yield and performance.

Implementation Method 1

detecting at least one inconsistency at a surface of a semiconductor substrate

Methodology Applied

Scientific EffectSurface inspection/detection:

Implementation Method 2

A material is selectively deposited on the substrate according to the deposition pattern

Methodology Applied

Scientific EffectSelective deposition: Deposition (physical)

Implementation Method 3

front wiring for collecting electrical current produced by the solar cell device

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11742442B2Method of processing inconsistencies in solar cell devices and devices formed thereby

Publication Date: 2023.08.29 THE BOEING CO

AI summary

The present disclosure is directed to a method of processing a solar cell device. The method comprises detecting at least one inconsistency at a surface of a semiconductor substrate having a solar cell active region formed therein. A deposition pattern is determined based on the location of the at least one inconsistency. A material is selectively deposited on the substrate according to the deposition pattern.