公开(公告)号：US20160093757A1

公开(公告)日：2016-03-31

申请号：US14496226

申请日：2014-09-25

申请人： Thomas P. Pass ,  Gabriel Harley ,  David Fredric Joel Kavulak ,  Richard Hamilton Sewell

发明人： Thomas P. Pass ,  Gabriel Harley ,  David Fredric Joel Kavulak ,  Richard Hamilton Sewell

IPC分类号： H01L31/05 ,  B23K31/02 ,  H01L31/18

CPC分类号： H01L31/0512 ,  B23K31/02 ,  H01L31/05 ,  H01L31/0504 ,  H01L31/0508 ,  H01L31/0682 ,  H01L31/0745 ,  H01L31/18 ,  H01L31/1876 ,  Y02E10/50 ,  Y02E10/547

摘要： A solar cell can include a conductive foil having a first portion with a first yield strength coupled to a semiconductor region of the solar cell. The solar cell can be interconnected with another solar cell via an interconnect structure that includes a second portion of the conductive foil, with the interconnect structure having a second yield strength greater than the first yield strength.

摘要翻译： 太阳能电池可以包括具有与太阳能电池的半导体区域耦合的第一屈服强度的第一部分的导电箔。 太阳能电池可以通过包括导电箔的第二部分的互连结构与另一个太阳能电池互连，互连结构具有大于第一屈服强度的第二屈服强度。

公开(公告)号：US20170018667A1

公开(公告)日：2017-01-19

申请号：US15279950

申请日：2016-09-29

申请人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

发明人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

IPC分类号： H01L31/0368 ,  H01L31/0224 ,  H01L31/028

CPC分类号： H01L31/03682 ,  H01L31/022425 ,  H01L31/022441 ,  H01L31/028 ,  H01L31/0475 ,  H01L31/0745 ,  H01L31/1804 ,  Y02E10/547 ,  Y02P70/521

摘要： Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. A method involves patterning a first surface of a metal foil to provide a plurality of alternating grooves and ridges in the metal foil. Non-conductive material regions are formed in the grooves in the metal foil. The metal foil is located above a plurality of alternating N-type and P-type semiconductor regions disposed in or above a substrate to provide the non-conductive material regions in alignment with locations between the alternating N-type and P-type semiconductor regions and to provide the ridges in alignment with the alternating N-type and P-type semiconductor regions. The ridges of the metal foil are adhered to the alternating N-type and P-type semiconductor regions. The metal foil is patterned through the metal foil from a second surface of the metal foil at regions in alignment with the non-conductive material regions.

摘要翻译： 描述了用于太阳能电池和所得太阳能电池的箔基金属化的方法。 一种方法包括图案化金属箔的第一表面以在金属箔中提供多个交替的槽和脊。 在金属箔的凹槽中形成非导电材料区域。 金属箔位于设置在基板中或上方的多个交替的N型和P型半导体区域之上，以提供与交替的N型和P型半导体区之间的位置对准的非导电材料区域，以及 以提供与交替的N型和P型半导体区对准的脊。 金属箔的脊部粘附到交替的N型和P型半导体区域。 在与非导电材料区域对准的区域处，通过金属箔从金属箔的第二表面图案化金属箔。

公开(公告)号：US20160380132A1

公开(公告)日：2016-12-29

申请号：US14750821

申请日：2015-06-25

申请人： Richard Hamilton Sewell ,  David Fredric Joel Kavulak ,  Lewis Abra ,  Thomas P. Pass ,  Taeseok Kim ,  Matthieu Moors ,  Benjamin Ian Hsia ,  Gabriel Harley

发明人： Richard Hamilton Sewell ,  David Fredric Joel Kavulak ,  Lewis Abra ,  Thomas P. Pass ,  Taeseok Kim ,  Matthieu Moors ,  Benjamin Ian Hsia ,  Gabriel Harley

IPC分类号： H01L31/0224 ,  H01L31/0368 ,  H01L31/05 ,  H01L31/0687

摘要： Approaches for fabricating one-dimensional metallization for solar cells, and the resulting solar cells, are described. In an example, a solar cell includes a substrate having a back surface and an opposing light-receiving surface. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the back surface of the substrate and parallel along a first direction to form a one-dimensional layout of emitter regions for the solar cell. A conductive contact structure is disposed on the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal lines corresponding to the plurality of alternating N-type and P-type semiconductor regions. The plurality of metal lines is parallel along the first direction to form a one-dimensional layout of a metallization layer for the solar cell.

摘要翻译： 描述了制造用于太阳能电池的一维金属化的方法以及所得到的太阳能电池。 在一个示例中，太阳能电池包括具有背面和相对的光接收表面的基板。 多个交替的N型和P型半导体区域设置在基板的背面中或上方并且沿着第一方向平行，以形成用于太阳能电池的发射极区域的一维布局。 导电接触结构设置在多个交替的N型和P型半导体区域上。 导电接触结构包括对应于多个交替的N型和P型半导体区的多个金属线。 多个金属线沿着第一方向平行以形成用于太阳能电池的金属化层的一维布局。

公开(公告)号：US09461192B2

公开(公告)日：2016-10-04

申请号：US14572170

申请日：2014-12-16

申请人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

发明人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

IPC分类号： H01L21/00 ,  H01L31/0475 ,  H01L31/028 ,  H01L31/0224 ,  H01L31/18

CPC分类号： H01L31/03682 ,  H01L31/022425 ,  H01L31/022441 ,  H01L31/028 ,  H01L31/0475 ,  H01L31/0745 ,  H01L31/1804 ,  Y02E10/547 ,  Y02P70/521

摘要： Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. A method involves patterning a first surface of a metal foil to provide a plurality of alternating grooves and ridges in the metal foil. Non-conductive material regions are formed in the grooves in the metal foil. The metal foil is located above a plurality of alternating N-type and P-type semiconductor regions disposed in or above a substrate to provide the non-conductive material regions in alignment with locations between the alternating N-type and P-type semiconductor regions and to provide the ridges in alignment with the alternating N-type and P-type semiconductor regions. The ridges of the metal foil are adhered to the alternating N-type and P-type semiconductor regions. The metal foil is patterned through the metal foil from a second surface of the metal foil at regions in alignment with the non-conductive material regions.

摘要翻译： 描述了用于太阳能电池和所得太阳能电池的箔基金属化的方法。 一种方法包括图案化金属箔的第一表面以在金属箔中提供多个交替的槽和脊。 在金属箔的凹槽中形成非导电材料区域。 金属箔位于设置在基板中或上方的多个交替的N型和P型半导体区域之上，以提供与交替的N型和P型半导体区之间的位置对准的非导电材料区域，以及 以提供与交替的N型和P型半导体区对准的脊。 金属箔的脊部粘附到交替的N型和P型半导体区域。 在与非导电材料区域对准的区域处，通过金属箔从金属箔的第二表面图案化金属箔。

公开(公告)号：US20170133535A1

公开(公告)日：2017-05-11

申请号：US15410560

申请日：2017-01-19

申请人： Thomas P. Pass ,  Gabriel Harley ,  David Fredric Joel Kavulak ,  Richard Hamilton Sewell

发明人： Thomas P. Pass ,  Gabriel Harley ,  David Fredric Joel Kavulak ,  Richard Hamilton Sewell

IPC分类号： H01L31/05 ,  H01L31/18

CPC分类号： H01L31/0512 ,  B23K31/02 ,  H01L31/05 ,  H01L31/0504 ,  H01L31/0508 ,  H01L31/0682 ,  H01L31/0745 ,  H01L31/18 ,  H01L31/1876 ,  Y02E10/50 ,  Y02E10/547

摘要： A solar cell can include a conductive foil having a first portion with a first yield strength coupled to a semiconductor region of the solar cell. The solar cell can be interconnected with another solar cell via an interconnect structure that includes a second portion of the conductive foil, with the interconnect structure having a second yield strength greater than the first yield strength.

公开(公告)号：US20160172516A1

公开(公告)日：2016-06-16

申请号：US14572170

申请日：2014-12-16

申请人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

发明人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Thomas P. Pass

IPC分类号： H01L31/0475 ,  H01L31/0224 ,  H01L31/18 ,  H01L31/028

CPC分类号： H01L31/03682 ,  H01L31/022425 ,  H01L31/022441 ,  H01L31/028 ,  H01L31/0475 ,  H01L31/0745 ,  H01L31/1804 ,  Y02E10/547 ,  Y02P70/521

摘要： Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. A method involves patterning a first surface of a metal foil to provide a plurality of alternating grooves and ridges in the metal foil. Non-conductive material regions are formed in the grooves in the metal foil. The metal foil is located above a plurality of alternating N-type and P-type semiconductor regions disposed in or above a substrate to provide the non-conductive material regions in alignment with locations between the alternating N-type and P-type semiconductor regions and to provide the ridges in alignment with the alternating N-type and P-type semiconductor regions. The ridges of the metal foil are adhered to the alternating N-type and P-type semiconductor regions. The metal foil is patterned through the metal foil from a second surface of the metal foil at regions in alignment with the non-conductive material regions.

摘要翻译： 描述了用于太阳能电池和所得太阳能电池的箔基金属化的方法。 一种方法包括图案化金属箔的第一表面以在金属箔中提供多个交替的槽和脊。 在金属箔的凹槽中形成非导电材料区域。 金属箔位于设置在基板中或上方的多个交替的N型和P型半导体区域之上，以提供与交替的N型和P型半导体区之间的位置对准的非导电材料区域，以及 以提供与交替的N型和P型半导体区对准的脊。 金属箔的脊部粘附到交替的N型和P型半导体区域。 在与非导电材料区域对准的区域处，通过金属箔从金属箔的第二表面图案化金属箔。

公开(公告)号：US20170162723A1

公开(公告)日：2017-06-08

申请号：US14958739

申请日：2015-12-03

申请人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Lewis Abra ,  Matthieu Moors ,  George Nadim Mseis ,  Ludovic Pierre Edmond Hudanski

发明人： David Fredric Joel Kavulak ,  Gabriel Harley ,  Lewis Abra ,  Matthieu Moors ,  George Nadim Mseis ,  Ludovic Pierre Edmond Hudanski

IPC分类号： H01L31/02

CPC分类号： H01L31/02008 ,  H01L31/0508 ,  Y02E10/50

摘要： Approaches for fabricating spot-welded and adhesive bonded interconnects for solar cells, and the resulting solar cells, are described. In an example, a solar cell includes a substrate having a back surface and an opposing light-receiving surface. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the back surface of the substrate. A conductive contact structure is disposed on the plurality of alternating N-type and P-type semiconductor regions. An interconnect structure is electrically connected to the conductive contact structure. The interconnect structure includes a plurality of protrusions in contact with the conductive contact structure. Each of the plurality of protrusions is spot-welded to the conductive contact structure and is surrounded by an adhesive material.

公开(公告)号：US20160380127A1

公开(公告)日：2016-12-29

申请号：US14752828

申请日：2015-06-26

申请人： Richard Hamilton Sewell ,  David Fredric Joel Kavulak ,  Taeseok Kim ,  Gabriel Harley

发明人： Richard Hamilton Sewell ,  David Fredric Joel Kavulak ,  Taeseok Kim ,  Gabriel Harley

IPC分类号： H01L31/0224 ,  H01L31/0216 ,  H01L31/18

CPC分类号： H01L31/022441 ,  H01L31/0682 ,  H01L31/1804 ,  Y02E10/547 ,  Y02P70/521

摘要： Approaches for fabricating foil-based metallization of solar cells based on a leave-in etch mask, and the resulting solar cells, are described. In an example, a solar cell includes a substrate having a back surface and an opposing light-receiving surface. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the back surface of the substrate. A conductive contact structure is disposed on the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes metal foil portions in alignment with corresponding ones of the alternating N-type and P-type semiconductor regions. A patterned wet etchant-resistant polymer layer is disposed on the conductive contact structure. Portions of the patterned wet etchant-resistant polymer layer are disposed on and in alignment with the metal foil portions.

摘要翻译： 描述了基于留下蚀刻掩模和所得到的太阳能电池来制造基于箔的金属化太阳能电池的方法。 在一个示例中，太阳能电池包括具有背面和相对的光接收表面的基板。 多个交替的N型和P型半导体区域设置在衬底的背面中或上方。 导电接触结构设置在多个交替的N型和P型半导体区域上。 导电接触结构包括与交替的N型和P型半导体区域中的对应的金属箔部分对准的金属箔部分。 图案化的耐湿蚀刻剂聚合物层设置在导电接触结构上。 图案化的耐湿蚀刻剂聚合物层的一部分设置在金属箔部分上并与之对齐。

公开(公告)号：US20160133759A1

公开(公告)日：2016-05-12

申请号：US14997368

申请日：2016-01-15

申请人： Thomas P. Pass ,  Gabriel Harley

发明人： Thomas P. Pass ,  Gabriel Harley

IPC分类号： H01L31/02

CPC分类号： H01L31/02008 ,  H01L31/02021 ,  H01L31/022441 ,  H01L31/0516 ,  H01L31/0745 ,  H01L31/18 ,  Y02E10/50

摘要： Foil trim approaches for the foil-based metallization of solar cells and the resulting solar cells are described. For example, a method involves attaching a metal foil sheet to a metallized surface of an underlying supported wafer to provide a unified pairing of the metal foil sheet and the wafer. Subsequent to attaching the metal foil sheet, a portion of the metal foil sheet is laser scribed from above to form a groove in the metal foil sheet. Subsequent to laser scribing the metal foil sheet, the unified pairing of the metal foil sheet and the wafer is rotated to provide the metal sheet below the wafer. Subsequent to the rotating, the unified pairing of the metal foil sheet and the wafer is placed on a chuck with the metal sheet below the wafer. The metal foil sheet is torn at least along the groove to trim the metal foil sheet.

摘要翻译： 描述了用于太阳能电池的箔基金属化和所得到的太阳能电池的箔修剪方法。 例如，一种方法包括将金属箔片附着到下面的支撑晶片的金属化表面上，以提供金属箔片和晶片的统一配对。 在附着金属箔片之后，金属箔片的一部分从上方被激光划刻以在金属箔片中形成凹槽。 在金属箔片的激光划线之后，金属箔片和晶片的统一配对旋转，以在金属片下面提供金属片。 在旋转之后，将金属箔片和晶片的统一配对放置在具有金属片在晶片下方的卡盘上。 金属箔片至少沿着沟槽撕开以修整金属箔片。

公开(公告)号：US09257575B1

公开(公告)日：2016-02-09

申请号：US14490552

申请日：2014-09-18

申请人： Thomas P. Pass ,  Gabriel Harley

发明人： Thomas P. Pass ,  Gabriel Harley

IPC分类号： H01L31/02 ,  H01L21/00 ,  H01L31/0368 ,  H01L31/028 ,  H01L31/0304 ,  H01L31/18

CPC分类号： H01L31/02008 ,  H01L31/02021 ,  H01L31/022441 ,  H01L31/0516 ,  H01L31/0745 ,  H01L31/18 ,  Y02E10/50

摘要： Foil trim approaches for the foil-based metallization of solar cells and the resulting solar cells are described. For example, a method involves attaching a metal foil sheet to a metallized surface of an underlying supported wafer to provide a unified pairing of the metal foil sheet and the wafer. Subsequent to attaching the metal foil sheet, a portion of the metal foil sheet is laser scribed from above to form a groove in the metal foil sheet. Subsequent to laser scribing the metal foil sheet, the unified pairing of the metal foil sheet and the wafer is rotated to provide the metal sheet below the wafer. Subsequent to the rotating, the unified pairing of the metal foil sheet and the wafer is placed on a chuck with the metal sheet below the wafer. The metal foil sheet is torn at least along the groove to trim the metal foil sheet.

摘要翻译： 描述了用于太阳能电池的箔基金属化和所得到的太阳能电池的箔修剪方法。 例如，一种方法包括将金属箔片附着到下面的支撑晶片的金属化表面上，以提供金属箔片和晶片的统一配对。 在附着金属箔片之后，金属箔片的一部分从上方被激光划刻以在金属箔片中形成凹槽。 在金属箔片的激光划线之后，金属箔片和晶片的统一配对旋转，以在金属片下面提供金属片。 在旋转之后，将金属箔片和晶片的统一配对放置在具有金属片在晶片下方的卡盘上。 金属箔片至少沿着沟槽撕开以修整金属箔片。