Textured Solar Cell Grid Areas for Grid-Line Adhesion

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Solution Overview

Problem

Existing solar cells face issues with weak bonding between grid lines and solar cell slices, leading to a high probability of grid line detachment during usage.

Innovation Solution

A solar cell design featuring a substrate with a first textured surface and multiple grid-line areas with second textured surfaces, where sheet-shaped anti-reflection films are formed on the second textured surfaces to increase contact area and bonding strength between grid lines and the substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electroplating processes are used to form grid lines on the solar cell surface, then grid lines can be formed efficiently, but the bonding between grid lines and solar cell slice becomes weak leading to detachment

Engineering Contradiction:

Improvegrid line formation efficiencyVSAvoidbonding strength between grid lines and solar cell slice

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The grid-line area is divided into multiple portions (first portion, second portion, third portion) with different textured surface structures. The first and third portions have pyramid structures that provide strong bonding, while the second portion has different structures. This segmentation allows different regions to serve different functions: bonding strength and electrical contact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the grid-line area are given different local structures: the first and third portions have pyramid structures with specific height ratios (0.3-0.9 times the original pyramid height) optimized for bonding, while the second portion has different characteristics. This local quality variation optimizes both bonding strength and electrical conductivity in different regions.

Inventive Principle:

Principle #3Local quality

2Reliability

If the contact area between grid lines and substrate is increased to improve bonding strength, then the bonding strength improves, but the device complexity increases

Engineering Contradiction:

Improvebonding strength between grid lines and substrateVSAvoidstructural complexity of grid-line area

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The solution transitions from a two-dimensional planar contact to a three-dimensional textured surface contact. By creating pyramid structures with specific height ratios (0.3-0.9 times the original pyramid height) in the grid-line area, the contact area is increased in the vertical dimension, significantly improving bonding strength without requiring complex lateral expansions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12278302B2Solar cell and method for producing the same

Publication Date: 2025.04.15 ZHEJIANG JINKO SOLAR CO LTD

AI summary

Embodiments of the present disclosure relate to a solar cell and a method for producing the same. The solar cell includes: a substrate having a first textured surface, a plurality of sheet-shaped anti-reflection films, and a plurality of grid lines. A plurality of grid-line areas spaced from each other are formed on the first textured surface, and each grid-line area has a second textured surface. One or more sheet-shaped anti-reflection films of the plurality of sheet-shaped anti-reflection films are formed on a portion of the second textured surface of each grid-line area. Each grid line of the plurality of grid lines is formed on a respective grid-line area, and each grid line is in contact with the one or more sheet-shaped anti-reflection films and with a remaining portion of the second textured surface of the respective grid-line area not covered by any sheet-shaped anti-reflection films. grid linegrid line.