Textured Solar Cell Electrode Layout for Simpler High-Precision Fabrication
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Solution Overview
Problem
Conventional solar cell preparation methods are cumbersome due to the need for multiple masks and etchings to achieve accurate film layer settings and coordination, limiting the improvement of solar cell efficiency.
Innovation Solution
A solar cell design with alternating electrode and non-electrode regions, featuring distinct surface structures for each region, along with a tunneling dielectric layer and a doped conductive layer, to enhance light utilization and reduce surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks and etchings are used to achieve accurate film layer settings and coordination, then the manufacturing precision is improved, but the device complexity and ease of manufacture deteriorate
Solution Approach 1:
The substrate surface is segmented into electrode regions and non-electrode regions with different surface structures (first surface structure with smaller roughness, second surface structure with larger roughness including protrusion structures). This spatial segmentation allows different regions to have optimized properties without requiring multiple masks and etchings, thus maintaining manufacturing precision while reducing process complexity
Solution Approach 2:
Different surface structures are applied to different regions: the electrode regions have a first surface structure with smaller roughness for better electrical contact, while the non-electrode regions have a second surface structure with larger roughness for enhanced light trapping. This local quality differentiation achieves accurate film layer coordination through regional optimization rather than multiple global processing steps
2Manufacturing precision
If multiple masks and etchings are used to achieve accurate film layer settings and coordination, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The substrate is pre-formed with alternating electrode and non-electrode regions having different surface structures before the main film deposition process. This preliminary action of creating regionally differentiated surfaces allows subsequent film layers to be deposited in a single coordinated process, achieving high manufacturing precision without requiring multiple sequential masks and etchings, thereby improving productivity
3Reliability
If the first surface structure has smaller roughness, then the contact resistance is reduced, but the light reflection and utilization deteriorate
Solution Approach 1:
The electrode regions are given a first surface structure with smaller roughness to reduce contact resistance and improve electrical reliability, while the non-electrode regions are given a second surface structure with larger roughness including protrusion structures to enhance light trapping and reduce reflection. This local quality differentiation allows each region to be optimized for its specific function without compromising the other
Solution Approach 2:
The substrate surface is segmented into functionally distinct electrode regions and non-electrode regions with different surface structures. The electrode regions have smooth surfaces for electrical contact, while the non-electrode regions have rough surfaces with protrusions for light management. This segmentation enables simultaneous optimization of both electrical and optical properties across different areas
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 proposed design improves the photoelectric conversion efficiency of the solar cell by optimizing surface structures for better light reflection and utilization, while reducing contact resistance and enhancing passivation effects.
Implementation Method 1
a tunneling dielectric layer formed over the first surface structure
Implementation Method 2
the second surface structure includes multiple first protrusion structures... optimizing surface structures for better light reflection and utilization
Implementation Method 3
a first doped conductive layer formed over the tunneling dielectric layer... a second doped conductive layer formed over the intrinsic passivation layer
Implementation Method 4
a passivation layer formed over the non-electrode regions and the first doped conductive layer... enhancing passivation effects
Data Source
Figure 1~2
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AI summary
The embodiments of the present application relate to the technical field of photovoltaics, a solar cell, a method for preparing a solar cell, and a photovoltaic module are provided. The solar cell includes a substrate having electrode regions and non-electrode regions, and the electrode regions are arranged alternatingly with the non-electrode regions. Each of the electrode regions has a first surface structure, each of the non-electrode regions has a second surface structure, the electrode regions have surface roughness less than surface roughness of the non-electrode regions. The second surface structure includes multiple first protrusion structures. The solar cell further includes a tunneling dielectric layer formed over the first surface structure, a first doped conductive layer formed over the tunneling dielectric layer, a passivation layer formed over the non-electrode regions and the first doped conductive layer, and multiple first electrodes formed over respective ones of the electrode regions. The multiple first electrodes penetrate the passivation layer to be in electrical contact with the first doped conductive layer.