Solar Cell Gate Line Layout for Lower Silver Paste Use
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Solution Overview
Problem
The high cost of silver in solar cells due to its extensive use in screen printing technology, which is difficult to replace, necessitates a reduction in silver consumption while maintaining cell efficiency.
Innovation Solution
A gate line structure for solar cells featuring disconnected sections on thin gate lines between main gate lines, optimizing silver paste usage by arranging these sections at specific positions to reduce consumption and ensure efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screen printing technology is used with continuous thin gate lines, then electrical conductivity is improved, but silver paste consumption increases
Solution Approach 1:
The thin gate lines are divided into multiple segments with disconnected sections between main gate lines. Each segment is separated by a gap, transforming the continuous line into a discontinuous structure. This segmentation reduces the total length of silver paste required while maintaining electrical conductivity through alternative current paths via main gate lines and conductive adhesive material in the gaps.
Solution Approach 2:
Instead of providing continuous coverage with thin gate lines, the invention uses partial coverage by introducing disconnected sections. The gaps between segments are filled with conductive adhesive material that provides sufficient conductivity without requiring complete continuous silver paste coverage, achieving adequate electrical performance with reduced material usage.
2Quantity of substance
If silver paste consumption is reduced, then production cost decreases, but cell efficiency may be compromised
Solution Approach 1:
The gate line structure employs different configurations in different regions: continuous main gate lines provide primary current collection, while thin gate lines are disconnected in specific regions between main gate lines. The gaps are strategically positioned and filled with conductive adhesive material, creating local variations in conductivity that optimize both material usage and electrical performance across different areas of the cell.
Solution Approach 2:
The conductive adhesive material serves as an intermediary between the disconnected thin gate line segments and the main gate lines. This intermediate material bridges the gaps, providing electrical connection paths that maintain cell efficiency without requiring continuous silver paste, thus enabling reduced silver consumption while preserving functionality.
3Quantity of substance
If electroplating is used to reduce silver consumption, then silver paste consumption decreases, but waste liquid production increases
Solution Approach 1:
The invention uses screen printing with disposable silver paste to create the gate line structure, replacing the electroplating process. This approach accepts the consumable nature of screen printing paste as a one-time material that forms the desired pattern, avoiding the repeated use of toxic chemicals and waste liquid generation associated with electroplating baths, while achieving comparable or better silver reduction.
Data Source
AI summary
The present disclosure provides a gate line structure of a solar cell and a solar cell applying same. The structure comprises a plurality of main gate lines extending along a first direction and arranged at intervals along a second direction, and a plurality of thin gate lines extending along the second direction and arranged at intervals along the first direction, wherein the first direction and the second direction are not parallel, the plurality of main gate lines are electrically connected to the plurality of thin gate lines respectively, and between any two adjacent main gate lines, each thin gate line has a disconnected section. According to the gate line structure of a solar cell and a solar cell applying same of the present disclosure, silver paste consumption can be effectively reduced while ensuring cell efficiency, reducing the preparation costs of a solar cell.