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    LEAVE-IN ETCH MASK FOR FOIL-BASED METALLIZATION OF SOLAR CELLS
    1.
    发明申请
    LEAVE-IN ETCH MASK FOR FOIL-BASED METALLIZATION OF SOLAR CELLS 有权

    公开(公告)号：US20210057593A1

    公开(公告)日：2021-02-25

    申请号：US17082995

    申请日：2020-10-28

    申请人： SunPower Corporation

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

    IPC分类号： H01L31/0224 ,  H01L31/068 ,  H01L31/18

    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.

    Single-step metal bond and contact formation for solar cells
    5.
    发明授权
    Single-step metal bond and contact formation for solar cells 有权

    公开(公告)号：US10566474B2

    公开(公告)日：2020-02-18

    申请号：US16167379

    申请日：2018-10-22

    申请人： SunPower Corporation ,  Total Marketing Services

    发明人： Matthieu Moors ,  Taeseok Kim

    IPC分类号： H01L31/0224 ,  H01L31/18 ,  H01L31/068

    摘要： A method for fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a first metal layer on the dielectric region. The method can also include forming a second metal layer on the first metal layer and locally heating a particular region of the second metal layer, where heating includes forming a metal bond between the first and second metal layer and forming a contact between the first metal layer and the solar cell structure. The method can include forming an adhesive layer on the first metal layer and forming a second metal layer on the adhesive layer, where the adhesive layer mechanically couples the second metal layer to the first metal layer and allows for an electrical connection between the second metal layer to the first metal layer.

    Foil-based metallization of solar cells
    7.
    发明授权
    Foil-based metallization of solar cells 有权

    公开(公告)号：US10090421B2

    公开(公告)日：2018-10-02

    申请号：US15485840

    申请日：2017-04-12

    申请人： SUNPOWER CORPORATION

    发明人： Gabriel Harley ,  Taeseok Kim ,  Richard Hamilton Sewell ,  Michael Morse ,  David D. Smith ,  Matthieu Moors ,  Jens-Dirk Moschner

    IPC分类号： H01L31/0224 ,  H01L31/0475 ,  H01L31/028 ,  H01L31/05

    摘要： Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. In an example, a solar cell includes a substrate. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the substrate. A conductive contact structure is disposed above the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal seed material regions providing a metal seed material region disposed on each of the alternating N-type and P-type semiconductor regions. A metal foil is disposed on the plurality of metal seed material regions, the metal foil having anodized portions isolating metal regions of the metal foil corresponding to the alternating N-type and P-type semiconductor regions.

    Patterned thin foil
    8.
    发明授权
    Patterned thin foil 有权
    图案薄箔

    公开(公告)号：US09502596B2

    公开(公告)日：2016-11-22

    申请号：US13931538

    申请日：2013-06-28

    申请人： SunPower Corporation

    发明人： Thomas Pass ,  Richard Sewell ,  Taeseok Kim ,  Gabriel Harley ,  David F. J. Kavulak ,  Xiuwen Tu

    IPC分类号： H01L31/0224 ,  H01L31/04 ,  H01L31/05 ,  H01L31/068 ,  H01L31/18 ,  H01L31/048

    CPC分类号： H01L31/0512 ,  H01L31/048 ,  H01L31/0488 ,  H01L31/049 ,  H01L31/0516 ,  H01L31/1876 ,  Y02E10/50 ,  Y02P70/521

    摘要： An adhesive may be applied to a surface of a reusable carrier. Metal foil may be attached to the adhesive to couple the metal foil to the surface of the reusable carrier. The metal foil may be patterned without damaging the reusable carrier. A semiconductor structure (e.g., a solar cell) may be attached to the patterned metal foil. The reusable carrier may then be removed. In some embodiments, the semiconductor structure may be encapsulated using an encapsulant, with the adhesive being compatible with the encapsulant.

    摘要翻译： 可以将粘合剂施加到可重复使用的载体的表面。 金属箔可以附着到粘合剂上以将金属箔耦合到可重复使用的载体的表面。 金属箔可以被图案化而不损坏可重复使用的载体。 半导体结构（例如，太阳能电池）可以附接到图案化的金属箔。 然后可以移除可重复使用的载体。 在一些实施例中，半导体结构可以使用密封剂进行封装，粘合剂与密封剂相容。

    Solar cells with silicon nanoparticles that are coated with nanoparticle passivation film
    9.
    发明授权
    Solar cells with silicon nanoparticles that are coated with nanoparticle passivation film 有权
    具有纳米颗粒钝化膜的硅纳米颗粒的太阳能电池

    公开(公告)号：US09142696B2

    公开(公告)日：2015-09-22

    申请号：US14460624

    申请日：2014-08-15

    申请人： SunPower Corporation

    发明人： Paul Loscutoff ,  Steven Molesa ,  Taeseok Kim

    IPC分类号： H01L35/24 ,  H01L51/00 ,  H01L31/0216 ,  H01L31/18 ,  H01L31/0384 ,  H01L31/0224 ,  H01L31/0368 ,  B82Y30/00

    CPC分类号： H01L31/02167 ,  B82Y30/00 ,  H01L31/022458 ,  H01L31/03682 ,  H01L31/03845 ,  H01L31/18

    摘要： A laser contact process is employed to form contact holes to emitters of a solar cell. Doped silicon nanoparticles are formed over a substrate of the solar cell. The surface of individual or clusters of silicon nanoparticles is coated with a nanoparticle passivation film. Contact holes to emitters of the solar cell are formed by impinging a laser beam on the passivated silicon nanoparticles. For example, the laser contact process may be a laser ablation process. In that case, the emitters may be formed by diffusing dopants from the silicon nanoparticles prior to forming the contact holes to the emitters. As another example, the laser contact process may be a laser melting process whereby portions of the silicon nanoparticles are melted to form the emitters and contact holes to the emitters.

    摘要翻译： 使用激光接触方法来形成与太阳能电池的发射体的接触孔。 在太阳能电池的衬底上形成掺杂的硅纳米颗粒。 单个或多个硅纳米颗粒的表面涂覆有纳米颗粒钝化膜。 通过将激光束照射在钝化的硅纳米颗粒上来形成与太阳能电池的发射体的接触孔。 例如，激光接触过程可以是激光烧蚀过程。 在这种情况下，可以通过在向发射体形成接触孔之前将来自硅纳米颗粒的掺杂剂扩散而形成发射体。 作为另一示例，激光接触工艺可以是激光熔化工艺，其中硅纳米颗粒的一部分被熔化以形成发射器和与发射器的接触孔。