TBC Solar Cell Isolation Structure for Lower-Cost Manufacturing
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Solution Overview
Problem
The manufacturing process of tunnel back contact (TBC) solar cells requires numerous process steps, leading to high manufacturing and mass production costs, which hinders their industrial scalability.
Innovation Solution
A manufacturing method for TBC solar cells involving the sequential stacking of tunnel oxide layers and doped layers on a silicon substrate, with an isolation structure to separate regions, reducing the number of process steps and improving efficiency by minimizing parasitic absorption and recombination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passivated contact structures are manufactured separately in P region and N region with more process steps, then contact and recombination rates are reduced, but manufacturing cost and mass production cost increase
Solution Approach 1:
The patent combines the manufacturing of passivated contact structures in P region and N region into a unified process. By integrating the formation of tunnel oxide layers and doped layers across both regions simultaneously, the number of process steps is reduced while maintaining the passivation effect, thereby lowering manufacturing costs without compromising reliability
Solution Approach 2:
The patent creates a multi-functional structure where the tunnel oxide layer and doped layer serve dual purposes: providing passivation for both P and N regions while establishing selective electrical contact. This universal structure eliminates the need for separate manufacturing processes for each region, reducing complexity and cost
2Reliability
If passivated contact structures are manufactured separately in P region and N region with more process steps, then contact and recombination rates are reduced, but mass production cost increases
Solution Approach 1:
The patent merges the manufacturing processes for P region and N region passivated contacts into a single integrated process flow. This consolidation enables simultaneous fabrication across both regions, increasing production throughput and reducing per-unit mass production costs while maintaining low contact and recombination rates
3Reliability
If tunnel oxide layers and doped layers are stacked sequentially, then parasitic absorption is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent segments the contact structure into distinct functional layers: tunnel oxide layer for passivation and doped layers for selective electrical contact. This segmentation allows each layer to be optimized independently for its specific function, minimizing parasitic absorption while the integrated manufacturing process keeps overall complexity manageable
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 reduces manufacturing costs, facilitates mass production, enhances cell efficiency by optimizing doping concentrations, and improves ohmic contact effects, thereby increasing the reliability and light utilization of the solar cells.
Implementation Method 1
A tunnel oxide passivated contact (TOPCon) cell has a passivated contact structure of a tunnel oxide layer and a doped polysilicon layer, which can effectively reduce rates of contact and recombination between a silicon wafer surface and metal
Implementation Method 2
A solar cell, also known as a photovoltaic cell, is a semiconductor device that converts light energy of sun directly into electrical energy
Data Source
AI summary
A solar cell and a photovoltaic module. The solar cell includes a substrate having a first surface and a second surface arranged oppositely, the second surface including a first region, a second region, and an isolation region located between the first region and the second region; a first tunnel oxide layer, a first doped layer, a second tunnel oxide layer, and a second doped layer located in the first region and sequentially stacked in a direction away from the substrate; the first tunnel oxide layer and a third doped layer located in the second region and sequentially stacked in a direction away from the substrate; and an isolation structure located in the isolation region and configured to isolate the first tunnel oxide layer located in the first region from the first tunnel oxide layer located in the second region, the isolation structure further configured to isolate the first doped layer and the second doped layer located in the first region from the third doped layer located in the second region.