Wet Etching Thin Film Solar Cell Separation

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Solution Overview

Problem

The existing methods for manufacturing thin film solar cells are limited by the time-consuming and costly laser scribing process, which reduces productivity and does not adequately secure a light-transmitting region for applications as building windows.

Innovation Solution

The proposed method involves forming a first electrode and separation part on a substrate, followed by an optoelectric conversion layer, a contact line, and a second electrode, with the use of a wet etching process to expose the first electrode and create a cell separation part, eliminating the need for laser scribing and enhancing productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser scribing process is used to form cell separation part, then cell separation is achieved, but production time increases and productivity decreases

Engineering Contradiction:

Improvecell separationVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the laser scribing process (thermal/optical system) with a wet etching process (chemical system) to form the cell separation part. The wet etching uses chemical solutions to remove materials and create separation structures, eliminating the need for laser equipment and significantly reducing production time while maintaining cell separation functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the process parameters from high-energy laser irradiation to controlled chemical etching conditions (etching solution composition, temperature, time). This parameter change enables the same cell separation function to be achieved more efficiently with shorter processing time and lower cost.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If laser scribing process is used to form cell separation part, then cell separation is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvecell separationVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent substitutes expensive laser scribing equipment and energy consumption with simpler wet etching equipment and chemical solutions. This replacement dramatically reduces manufacturing costs while achieving the same cell separation precision, making the process more economically viable for mass production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs disposable etching solutions and simple masking materials instead of expensive, durable laser equipment. The chemical etching process uses consumable materials that can be easily replaced, reducing capital investment and operational costs compared to maintaining expensive laser scribing systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Illumination intensity

If cell separation part is formed to ensure light transmission, then light-transmitting region is secured, but productivity decreases due to multiple laser scribing operations

Engineering Contradiction:

Improvelight transmissionVSAvoidnumber of processing steps

Core Design Contradiction:

Illumination intensityVSProductivity

Solution Approach 1:

The patent combines the cell separation formation and light-transmitting region creation into a single wet etching process step. By using appropriate masking patterns and etching conditions, both the cell separation part and the light-transmitting regions are formed simultaneously, eliminating the need for multiple sequential laser scribing operations and improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary patterning of the masking layer before wet etching to predefine both the cell separation locations and light-transmitting regions. This preliminary action ensures that when wet etching is applied, both features are created in one operation, securing light transmission requirements without requiring multiple processing steps.

Inventive Principle:

Principle #10Preliminary action

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 production time and cost, while ensuring sufficient light transmission for window applications by using a wet etching process to form the cell separation part, thereby improving the manufacturing efficiency and suitability of thin film solar cells for building integration.

Implementation Method 1

an etching process unit configured to remove the optoelectric conversion layer in the second separation part and expose the first electrode using an etching process

Methodology Applied

Scientific EffectWet etching:

Data Source

PatentUS9018034B2Apparatus and method for manufacturing of thin film type solar cell

Publication Date: 2015.04.28 JUSUNG ENG

AI summary

Disclosed is an apparatus and method for manufacturing a thin film type solar cell, which enables the enhancement of productivity, the apparatus for manufacturing a thin film type solar cell including a first electrode forming unit; a first separation part; an optoelectric conversion layer forming unit; a contact line forming unit; a printing unit; and an etching process unit, wherein the etching process unit removes the optoelectric conversion layer in a second separation part to expose the first electrode in the second separation part through a wet etching process.