Solar Cell Substrate Grooves to Prevent Scribing Shorts
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Solution Overview
Problem
The existing methods of manufacturing solar cells, which combine wafer type and thin film type solar cells, face issues such as layer short phenomena and degradation due to particles and cracks formed during the scribing process, leading to reduced power generation and quality of the finished solar cells.
Innovation Solution
The proposed method involves a substrate etching process that forms grooves and division parts on the substrate before forming thin film layers, including a first groove, a second groove, and a damage prevention part, to prevent layer shorts and enhance the quality of the solar cells by reducing the occurrence of particles and cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the scribing process is performed after forming thin film layers to divide cells, then the manufacturing process is simple, but layer short phenomenon occurs and power generation is reduced
Solution Approach 1:
The patent applies preliminary action by forming grooves in the substrate before depositing thin film layers. This prevents layer short phenomenon during the scribing process, as the grooves are already present in the substrate and do not require post-deposition scribing that would cause layer bonding and power generation reduction.
2Productivity
If the scribing process is performed to divide cells into unit cells, then cell division is achieved, but particles and cracks are formed degrading quality
Solution Approach 1:
The patent forms grooves in the substrate before thin film deposition, allowing cell division to occur along pre-defined groove lines. This eliminates the need for post-deposition scribing that causes particles and cracks, thereby maintaining high manufacturing precision and finished solar cell quality while achieving efficient cell division.
Solution Approach 2:
The patent segments the substrate into multiple cells by forming grooves that create physical divisions. These grooves serve as pre-defined division lines that guide subsequent cell separation, enabling clean division without the harmful effects of laser scribing through deposited layers.
3Reliability
If grooves are formed in substrate before thin film deposition, then layer short phenomenon is prevented and power generation increases, but manufacturing process complexity increases
Solution Approach 1:
The patent performs groove formation in the substrate before thin film deposition, which prevents layer short phenomenon and maintains power generation capability. Although this adds a step to the manufacturing process, it eliminates the need for complex post-deposition scribing processes and reduces defects, ultimately simplifying the overall manufacturing workflow.
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 decreases the likelihood of layer short phenomena, increases power generation, and enhances the quality of the solar cells by removing particles and cracks, thereby improving the overall efficiency and reliability of the solar cells.
Implementation Method 1
The scribing process may be performed by a scribing apparatus 300a which irradiates a laser beam onto the cell.
Data Source
AI summary
The present inventive concept relates to a solar cell manufacturing method, a solar cell manufactured thereby, and a substrate for a solar cell. The solar cell manufacturing method involves forming a separating portion for separating a substrate, which is for manufacturing the solar cell, into a plurality of pieces. The solar cell manufacturing method comprises: a step for preparing the substrate; a first substrate etching step for forming a first groove in one surface of the substrate; a second substrate etching step for forming a second groove inside the first groove; and a third substrate etching step for etching the substrate including the second groove, wherein the separating portion includes the first groove and the second groove.