Transfer Printing Assembly for Sub-25 μm Solar Cell Electrodes
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Solution Overview
Problem
Existing methods for forming electrode metal lines in silicon solar cells, such as screen printing and electroplating, face challenges in producing lines narrower than 25 μm and are costly, with high wastage of materials.
Innovation Solution
A transfer printing assembly comprising a carrier with a groove and a conducting wire, where the wire is partially or fully within the groove, allowing for precise control of electrode line width and reduced material wastage, and is detachable under external energy, facilitating the formation of narrow electrode lines with reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen printing method is used to form electrode metal lines, then the manufacturing process is simple, but the electrode line width cannot be controlled below 25 μm
Solution Approach 1:
The electrode formation process is segmented into multiple steps: (1) forming a metal layer pattern on the carrier, (2) transferring the pattern to the solar cell, and (3) removing the carrier. This segmentation enables precise width control below 25 μm while keeping the overall manufacturing process simple and compatible with existing production lines.
Solution Approach 2:
A carrier is introduced as an intermediary substrate to form the metal layer pattern before transferring it to the solar cell. This intermediary approach allows precise control of electrode line width during the formation stage, and the pattern is then transferred to achieve narrow electrode lines on the final product without requiring complex direct printing equipment.
2Manufacturing precision
If electroplating method is used to form electrode metal lines, then narrow electrode lines can be formed, but the manufacturing cost is high
Solution Approach 1:
Instead of using expensive electroplating processes, the invention creates a metal layer pattern on a carrier and transfers this pattern to the solar cell. This copying approach achieves comparable or better precision for narrow electrode lines while significantly reducing manufacturing costs by using simpler, more economical materials and processes.
Solution Approach 2:
The carrier serves as a disposable, low-cost substrate for forming the metal layer pattern. After the pattern is transferred to the solar cell, the carrier is removed and discarded. This approach replaces expensive electroplating equipment and processes with inexpensive, single-use carriers, thereby reducing overall manufacturing costs while maintaining precision.
3Loss of substance
If conventional printing methods are used, then material application is simple, but material wastage is high
Solution Approach 1:
The metal layer pattern is formed on the carrier in advance before transfer to the solar cell. This preliminary formation allows precise definition of the electrode line pattern and boundaries, ensuring that material is deposited only where needed. During the transfer process, this pre-formed pattern minimizes material wastage compared to direct printing methods.
4Reliability
If electroplating method is used, then electrode lines can be formed, but the manufacturing cost increases significantly
Solution Approach 1:
The invention copies the electrode pattern from a carrier to the solar cell, achieving reliable electrical connectivity through the transferred metal layer. This copying method produces electrode lines with sufficient conductivity and reliability while avoiding the high costs associated with electroplating equipment, materials, and processing.
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 transfer printing assembly enables the formation of narrow electrode lines with controlled width and reduced material wastage, lowering manufacturing costs compared to electroplating and screen printing methods, while maintaining effective electrical connectivity.
Implementation Method 1
The first conducting wire is detachable from the first groove under an action of external energy
Data Source
AI summary
The present application relates to a transfer printing assembly, a solar cell, and a preparation method thereof. The transfer printing assembly includes a carrier and a first conducting wire. The carrier includes a first surface having a first groove. The first conducting wire is at least partially disposed within the first groove. The first conducting wire and a wall of the first groove define a first receiving cavity at a side of the first conducting wire adjacent to an opening of the first groove. The first receiving cavity is configured to accommodate slurry material. The first conducting wire is detachable from the first groove under an action of external energy.