• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Metallization of Solar Cells Using Sheet Metal A solar cell structure includes p-type and n-type doped regions. a dielectric spacer is formed on a solar cell structure surface (201). a metal layer is formed in the dielectric spacer on the surface of the solar cell structure that is exposed to the dielectric spacer (202). a sheet of metal is placed over the metal layer (203). a laser beam is used to weld the sheet metal to the metal layer (204). a laser beam is also used for patterning the sheet metal (204). a laser beam ablates portions of the sheet metal and metal layer that lie on top of the dielectric spacer. laser ablation of the sheet metal cuts the sheet metal into separate p-type and n-type metal strips.
    公开号:BR112016006585B1
    申请号:R112016006585-9
    申请日:2014-09-22
    公开日:2021-08-03
    发明作者:Thomas Pass
    申请人:Sunpower Corporation；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [0001] The subject modalities described here generally refer to solar cells. More particularly, the subject modalities refer to solar cell fabrication processes and structures. BACKGROUND
    [0002] Solar cells are well known devices for converting solar radiation into electrical energy. A solar cell has a front side that faces the Sun during normal operation to collect solar radiation and a rear side opposite the front side. Solar radiation impinging on the solar cell creates electrical charges that can be collected to drive an external electrical circuit, such as a load. The external electrical circuit can receive electrical current from the solar cell through metal strips that are connected to doped regions of the solar cell. BRIEF SUMMARY
    [0003] In one embodiment, a dielectric spacer is formed on a surface of a solar cell structure. A metal layer is formed on the dielectric spacer and on the surface of the solar cell structure, which is exposed by the dielectric spacer. A sheet of metal is placed over the metal layer. A laser beam is used to weld the sheet metal to the metal layer. A laser beam is also used for patterning the sheet metal. The laser beam ablates portions of the sheet metal and metal layer that lie on top of the dielectric spacer. Laser ablation of sheet metal cuts the sheet metal into separate P-type and N-type metal strips.
    [0004] These and other features of this exhibit will be readily apparent to persons of ordinary skill in the art upon reading the entirety of this exhibit, which includes the associated drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS
    [0005] A more complete understanding of the subject can be derived by reference to the detailed description and claims, when considered in conjunction with the following figures, in which like reference numerals refer to similar elements throughout the figures. Drawings are not drawn to scale.
    [0006] Figures 1 to 7 are cross-sectional views that schematically illustrate a method of manufacturing a solar cell according to an embodiment of the present disclosure.
    [0007] Figure 8 is a plan view of a non-standard sheet metal according to an embodiment of the present disclosure.
    [0008] Figure 9 is a plan view of the sheet metal of Figure 8, after standardization, according to an embodiment of the present exhibition.
    [0009] Figure 10 is a flowchart of a method of manufacturing a solar cell according to an embodiment of the present disclosure.
    [0010] Figures 11 and 12 are cross-sectional views that schematically illustrate the patterning of a metal sheet at the module level, according to an embodiment of the present exhibition.
    [0011] Figures 13 and 14 are cross-sectional views schematically illustrating the use of a metal sheet with a patterned metal layer, according to an embodiment of the present disclosure. DETAILED DESCRIPTION
    [0012] The following detailed description is merely illustrative in nature and is not intended to limit the modalities of the subject or the application and uses of those modalities. As used here, the words “example” means “serving as an example, an instance or an illustration”. Any implementation described here as an example is not necessarily to be constructed as preferred or advantageous over other implementations. Furthermore, it is not intended to be delimited by any express or implied theory presented in the foregoing technical field, in the background, brief summary, or in the detailed description below.
    [0013] This descriptive report includes references to “a modality” or “a modality”. The appearances of the phrases “in a modality” or “in modality” do not necessarily refer to the same modality. Particular features, structures or features may be combined in any suitable manner consistent with this display.
    [0014] In the present exposition, several specific details are provided, such as examples of structures and methods, for the provision of a complete understanding of modalities. Those of ordinary skill in the art will recognize, however, that the modalities can be practiced without one or more of the specifics. In other cases, well-known details are not shown or described, to avoid obscuring aspects of the modalities.
    [0015] Figures 1 to 7 are cross-sectional views schematically illustrating a method of manufacturing a solar cell according to an embodiment of the present disclosure. The solar cell is manufactured as an all-back contact solar cell in those N-type and P-type doped regions and the metal strips coupled to the N-type and P-type doped regions are on the rear side of the solar cell.
    [0016] Referring first to Figure 1, a solar cell structure 100 is shown in accordance with an embodiment of the present disclosure. In the example of Figure 1, the solar cell structure 100 comprises a plurality of N-type doped regions and alternating P-type doped regions that may be formed on a solar cell substrate 101 or external to the solar cell substrate 101. For example , the N-type and P-type doped regions can be formed by diffusion of N-type and P-type dopants, respectively, on the solar cell substrate 101. In another example, the N-type and P-type doped regions are formed in a separate layer of material, such as polysilicon, which is formed on top of the solar cell substrate 101. In this example, the N-type and P-type dopants are diffused into the polysilicon (which may or may not have open ditches ) for forming N-type and P-type doped regions in the polysilicon, rather than in the solar cell substrate 101. The solar cell substrate 101 may comprise a microcrystalline silicon wafer, for example.
    [0017] In the example of figure 1, the labels "N" and "P" schematically represent the doped regions of type N and type P or electrical connections with doped regions of type N and type P. more particularly, the labels "N" schematically represent N-type doped regions or exposed metal connections to N-type doped regions. Similarly, "P" labels schematically represent exposed P-type doped regions or exposed metal connections to doped regions of P-type. the solar cell structure 100 thus can represent the structure of a solar cell being fabricated after contact holes for the N-type and P-type doped regions have been formed, but before the metallization process for the formation of metal contact strips for the N-type and P-type doped regions.
    [0018] In the example of Figure 1, the N-type and P-type doped regions are on the rear side of the solar cell structure 100. The rear side of the solar cell structure 100 is opposite the front side, which is directed towards the Sun for collecting solar radiation during normal operation.
    [0019] Referring next to Figure 2, a plurality of dielectric spacers 103 is formed on the surface of the solar cell structure 100. In the example of Figure 2, a dielectric spacer 103 is formed in a region on the surface of the solar cell structure. solar cell 100 which is on an interface between adjacent N-type and P-type doped regions. As can be appreciated, the dielectric spacers 103 can also be formed in other regions, depending on the particularities of the solar cell structure 100.
    [0020] In one embodiment, the dielectric spacers 103 are printed onto the solar cell structure 100 by screen printing. Dielectric spacers 103 can also be formed using other dielectric forming processes, including spin coating or deposition (eg, chemical vapor deposition) followed by patterning (eg, masking and chemical etching ). The dielectric spacers 103 may comprise a dielectric material with optical absorbers, a firing-capable dielectric, etc. As a particular example, the dielectric spacers 103 may comprise polyimide (e.g. with titanium oxide filters) which is screen printed onto the solar cell structure 100 to a thickness of 1 to 10 microns. Generally speaking, the dielectric spacers 103 can be configured to have a thickness and composition that will block (e.g., by absorption or reflection) the laser beam employed in patterning sheet metal 105 (see Figure 5) and are compatible with the process employed for forming the overlay metal layer (eg Figure 3, metal layer 104).
    [0021] In the example of Figure 2, each of the dielectric spacers 103 is formed over an N-type doped region and a P-type doped region of the solar cell structure 100. As will be more evident below, in a metallization process Subsequently, a sheet metal is patterned using a laser, while the sheet metal is over the solar cell structure 100. The dielectric spacers 103 advantageously block laser beams that can penetrate the solar cell structure 100 during patterning. of sheet metal 105.
    [0022] As shown in Figure 3, a metal layer 104 is formed over the solar cell structure 100. The metal layer 104 provides an electrical connection for the N-type and P-type doped regions to the formed metal strips subsequently. In one embodiment, the metal layer 104 comprises a continuous cover metal coating that conforms over the dielectric spacers 103. For example, the metal layer 104 may comprise aluminum, which is formed over the dielectric spacers 103, as N-type doped regions and P-type doped regions by electrodeposition with cathode disintegration, deposition or some other process to a thickness of 100 Angstroms to 5 microns (eg 0.3 microns to 1 micron). Generally speaking, the metal layer 104 comprises a material that can be bonded to the metal sheet 105. For example, the metal layer 104 may comprise aluminum, to facilitate welding to an aluminum metal sheet 105. The metal layer 104 further electrically connects the N-type doped regions to the P-type doped regions in Figure 3. The metal layer 104 is subsequently patterned to separate the N-type doped regions from the P-type doped regions during a patterning of the sheet metal 105 .
    [0023] Referring next to Figure 4, sheet metal 105 is approximately located on top of solar cell structure 100. Sheet metal 105 is a "sheet metal" in that it comprises a prefabricated thin sheet of metal. Figure 8 is a plan view of sheet metal 105 at this stage of the manufacturing process. As shown in Figure 8, sheet metal 105 is not standardized. As will be more evident below, sheet metal 105 is subsequently patterned for forming solar cell metal strips after sheet metal 105 has been fitted to metal layer 104.
    [0024] Continuing from Figure 5, sheet metal 105 is placed on solar cell structure 100. Unlike metal that is deposited or coated on solar cell structure 100, sheet metal 105 is a prefabricated sheet. In one embodiment, sheet metal 105 comprises an aluminum sheet. Sheet metal 105 is placed over solar cell structure 100 in that it is not formed over solar cell structure 100. In one embodiment, sheet metal 105 is placed over solar cell structure 100 by adapting to the metal layer 104. The fitting process may include pressing the metal sheet 105 to the metal layer 104 so that the metal sheet 105 makes intimate contact with the metal layer 104. The fitting process may result in sheet metal 105 conforming to elements (e.g., protrusions) of metal layer 104. Vacuum can be used to press metal sheet 105 against metal layer 104 during welding; the pressure plate is removed by laser ablation.
    [0025] Figure 6 shows the structure of solar cell 100 after the metal sheet 105 is electrically bonded to the metal layer 104. In the example of Figure 6, the metal sheet 105 is welded to the metal layer 104 by directing a laser beam onto sheet metal 105, while sheet metal 105 is pressed against metal layer 104. The laser welding process creates solder joints 106 that electrically bond sheet metal 105 to metal layer 104. Because sheet metal 105 is non-standard at this stage of the manufacturing process, sheet metal 105 still electrically connects the N-type and P-type doped regions of the solar cell structure 100.
    [0026] Continuing with Figure 7, sheet metal 105 is patterned for forming strips of metal 108 and 109. In one embodiment, sheet metal 105 is patterned by ablating portions of sheet metal 105 and the layer of metal 104 which are over the dielectric spacers 103. Sheet metal 105 and metal layer 104 can be ablated using a laser beam. The laser ablation process can cut (see 107) sheet metal 105 into at least two separate pieces, with one piece being a strip of metal 108 that is electrically connected to the P-type doped regions. breaks the electrical connection of the N-type and P-type doped regions through the metal layer 104 and the metal sheet 105. The sheet metal 105 and the metal layer 104 are thus standardized in the same step, advantageously reducing the cost of manufacturing.
    [0027] Figure 9 is a plan view of the patterned sheet metal 105 of Figure 7 according to an embodiment of the present disclosure. Figure 9 shows that the cut 107 physically separates the metal strip 108 from the metal strip 109. In the example of Figure 9, the metal sheet 105 is patterned for forming intercalated metal strips 108 and 109. Other Strip Designs Metal can also be employed, depending on the solar cell.
    [0028] Returning to Figure 7, the laser ablation process uses a laser beam that cuts sheet metal 105 and metal layer 104 all the way through. Depending on the process window of the laser ablation process, the laser beam may also cut portions of but not through the dielectric spacer 103. The dielectric spacers 103 advantageously block laser beams that might otherwise reach and damage the solar cell structure 100. The dielectric spacers 103 advantageously protect the solar cell structure 100 from mechanical damage, such as during the adaptation of the sheet metal 105 to the metal layer 104. The dielectric spacers 103 can be left in the solar cell completed, so that its use does not necessarily involve an additional removal step after patterning of sheet metal 105.
    [0029] In light of the foregoing, one of ordinary skill in the art will appreciate that the modalities of the present exposition provide additional advantages hitherto unrealized. The use of metal sheets to form metal strips is relatively cost-effective compared to metallization processes that involve the deposition or surface coating of metal strips. The dielectric spacers 103 allow a laser welding process and a laser ablation process to be carried out in situ, i.e. one after the other in the same processing station. Dielectric spacers 103 also allow the use of a laser beam for patterning sheet metal 105 while sheet metal 105 is over solar cell structure 100. As can be appreciated, placement and alignment of a sheet metal is much easier compared to placing and aligning separate strips of metal strips with accuracy on the order of microns. Unlike chemical etching and other chemical-based patterning processes, patterning sheet metal 105 using a laser minimizes the amount of residue that can form on the solar cell being manufactured.
    [0030] It is to be further noted that, in the example of Figure 9, the metal layer 104 is patterned simultaneously with the metal sheet 105. This advantageously eliminates the extrinsic steps for patterning the metal layer 104 for separation of the P-type and N-type doped regions before welding and laser ablation.
    [0031] Figure 10 shows a flowchart of a method of manufacturing a solar cell according to an embodiment of the present disclosure. The method of Figure 10 can be performed on a solar cell structure with N-type and P-type doped regions. The method of Figure 10 can be performed at the cell level during solar cell fabrication or at the module level when the solar cell is connected and packaged with other solar cells. Note that, in various embodiments, the method of Figure 10 may include additional or fewer blocks than illustrated.
    [0032] In the method of Figure 10, a plurality of dielectric spacers are formed on a surface of the solar cell structure (step 201). Each of the dielectric spacers can be formed over an N-type doped region and a P-type doped region of the solar cell structure. Dielectric spacers can be formed by screen printing, spin coating or by deposition and patterning, for example. A metal layer thereafter is formed on the dielectric spacers and on the surface of the solar cell structure that is exposed between the dielectric spacers (step 202). In one embodiment, the metal layer is a continuous, shaping layer that is formed by a coating deposition. A metal sheet is fitted to the metal layer (step 203). In one embodiment, the sheet metal is welded to the metal layer using a laser beam (step 204). It is to be noted that non-laser based welding techniques can also be employed to weld the sheet metal to the metal layer. A laser beam can also be used to ablate portions of the sheet metal and metal layer that lie on top of the dielectric spacer (step 205). The laser ablation process standardizes the sheet metal into separate metal strips, and standardizes the metal layer to separate the P-type and N-type doped regions.
    [0033] The standardization of sheet metal 105 can be performed at the module level, when the solar cell being manufactured is packaged with other solar cells. In that example, sheet metal 105 can be fitted to metal layers 104 of a plurality of solar cell structures 100. This is illustrated schematically in Figure 11, in which a sheet metal 105A is fitted to metal layers 104 of two or more solar cell structures 100. Sheet metal 105A is the same as previously discussed sheet metal 105, except that sheet metal 105A covers the space of more than one solar cell structure 100. As shown in Figure 12, sheet metal 105A can be patterned by laser ablation while on solar cell structures 100. The laser ablation process can pattern sheet metal 105A into metal strips 108 and 109, as discussed previously . Sheet metal 105A can be cut after patterning for physical separation of solar cell structures 100. After patterning, portions of sheet metal 105A can also be left in place for chaining together adjacent solar cell structures 100 .
    [0034] In one embodiment, laser ablation of sheet metal 105A leaves a connection between strips of metal of opposite type from adjacent solar cell structures 100. This is illustrated schematically in the example of Figure 12, in which the sheet metal 105 is patterned so that a P-type metal strip 109 of the solar cell structure 100 is left connected to the N-type metal strip 108 of an adjacent solar cell structure 100, thereby electrically connecting the solar cell structures 100 in series. This advantageously saves the manufacturing steps at the module level, because the patterning of sheet metal 105A can be combined with the chaining of the solar cell structures 100.
    [0035] As explained, the metal layer 104 can be formed as a metal covering layer that electrically connects the P-type and N-type doped regions and thereafter standardized for the separation of the P-type and N-type doped regions of type N during a patterning of the sheet metal 105. In other embodiments, depending on the particulars of the manufacturing process, the metal layer 104 can be patterned before welding and laser ablation. This is schematically illustrated in Figure 13, where the metal layer 104 is formed over the P-type and N-type doped regions without an electrical connection thereof. For example, the metal layer 104 can be deposited by a coating deposition onto the dielectric spacers 103, the N-type doped regions and the P-type doped regions and then patterned (e.g., by masking and chemical etching ) for separating the N-type doped regions and the P-type doped regions, as shown in Figure 13. The sheet metal 105 can then be positioned over the patterned metal layer 104 and dielectric spacers 103, laser welded to the metal layer 104, and patterned by laser ablation, as previously described. Figure 14 schematically shows the N-type metal strips 108 and the P-type metal strips 109, after the laser ablation process in that modality. The laser ablation process cuts through sheet metal 105, but stops at dielectric spacers 103.
    [0036] The methods and structures for the manufacture of solar cells were exposed. While specific embodiments have been provided, it is to be understood that these embodiments are for purposes of illustration and not limitation. Many additional modalities will be evident to persons of ordinary skill in the art reading this exhibit.
    [0037] The scope of this exposition includes any feature or combination of features set forth herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any and all issues addressed here. Accordingly, new claims may be made during the filing of this order (or an order claiming priority thereto) for any combination of appeals. In particular, with reference to the appended claims, remedies from the dependent claims may be combined with those from the independent claims, and remedies from the respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in claims attached.
    权利要求:
    Claims (13)
    [0001]
    1. A method for fabricating a solar cell comprising: forming a dielectric spacer (103) in a region of a surface of a solar cell structure (100) that is on an interface between adjacent P-type and N-type doped regions, wherein the solar cell structure comprises the N-type doped region adjacent to the P-type doped region; forming a metal layer (104) on the dielectric spacer (103), the N-type doped region and the P-type doped region, wherein the metal layer (104) electrically connects the N-type doped region to the doped region of type P; placing a metal sheet (105) on the metal layer (104); and after placing the sheet metal (105) on the metal layer (104), patterning the sheet metal (105), wherein patterning the sheet metal (105) includes removing portions of the sheet metal (105) and the layer of metal (104) which are on the dielectric spacer (103), characterized in that the sheet metal (105) is placed on the metal layer (104) of the solar cell structure (100) and on the other metal layer of the other solar cell structure.
    [0002]
    The method of claim 1, characterized in that patterning the sheet metal (105) comprises directing a laser beam onto the sheet metal (105) to ablate the sheet metal (105).
    [0003]
    A method according to claim 2, characterized in that the laser beam also ablates at least a portion of the dielectric spacer (103) under the metal layer (104).
    [0004]
    The method of any one of claims 1 to 3, further comprising: welding the sheet metal (105) to the metal layer (104).
    [0005]
    The method of claim 4, characterized in that the sheet metal (105) is welded to the metal layer (104) by directing a laser beam onto the metal sheet (105).
    [0006]
    A method as claimed in any one of claims 1 to 5, characterized in that the metal layer (104) is formed on the dielectric spacer (103) by a coating deposition.
    [0007]
    Method according to any one of claims 1 to 6, characterized in that the sheet metal (105) is patterned into a P-type metal strip (109) and an N-type metal strip (108), and the P-type metal strip (109) is physically and electrically separate from the N-type metal strip (108).
    [0008]
    The method of claim 1, characterized in that patterning the sheet metal (105) includes leaving an electrical connection between metal strips of the solar cell structure (100) and the other solar cell structure.
    [0009]
    The method of claim 1, characterized in that forming the metal layer (104) includes depositing the metal layer (104) on portions of the surface of the solar cell structure (100) that are exposed by the dielectric spacer ( 103); and placing the sheet metal (105) includes fitting the sheet metal (105) to the metal layer (104).
    [0010]
    The method of claim 9, characterized in that fitting the sheet metal (105) to the metal layer (104) comprises placing an aluminum sheet sheet on the metal layer (104).
    [0011]
    11. A plurality of solar cell structures characterized by comprising a first solar cell structure and a second solar cell structure each comprising: an N-type doped region and a P-type doped region adjacent to each other; a dielectric spacer (103) on an interface between the adjacent N-type doped region and the adjacent P-type doped region; a first metal layer (104) over the dielectric spacer and the N-type doped region, wherein the first metal layer is electrically connected to the N-type doped region; and a second metal layer (104) over the dielectric spacer and the P-type doped region, wherein the second metal layer is electrically connected to the P-type doped region; a sheet metal (105A) placed on the metal layers (104) of the first solar cell structure (100) and the second solar cell structure, wherein the sheet metal (105A) comprises: a first strip of sheet metal (108) which is electrically bonded to the first metal layer; and a second strip of sheet metal (109) that is electrically bonded to the second layer of metal, wherein the sheet metal (105A) is placed on the metal layers (104) of the first solar cell structure (100) and the second solar cell structure such that the second sheet metal strip (109) of the first solar cell structure is electrically connected with the first sheet metal strip (108) of the adjacent second solar cell structure, thereby electrically connecting the two solar cell structures in series.
    [0012]
    A plurality of structures according to claim 11, characterized in that the first and second strips of sheet metal comprise aluminium.
    [0013]
    A plurality of structures according to claim 11 or 12, characterized in that it further comprises: welding joints affixing the first strip of sheet metal to the first layer of metal and the second strip of sheet metal to the second layer of metal .
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    法律状态:
    2020-06-16| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-12-22| B25G| Requested change of headquarter approved|Owner name: SUNPOWER CORPORATION (US) |
    2021-05-25| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-08-03| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 22/09/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/040,047|2013-09-27|
    US14/040,047|US9437756B2|2013-09-27|2013-09-27|Metallization of solar cells using metal foils|
    PCT/US2014/056794|WO2015047952A1|2013-09-27|2014-09-22|Metallization of solar cells using metal foils|
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