Metallization of conductive wires for solar cells

• US 10,084,098 B2
• Filed: 09/30/2016
• Issued: 09/25/2018
• Est. Priority Date: 09/30/2016
• Status: Active Grant

• Current Assignee: Maxeon Solar Pte Limited
• Original Assignee: Sunpower Corporation (Totalenergies Se), Total Marketing Services And Total Energies Nouvelles Activites USA
• Inventors: Sewell, Richard Hamilton, Barkhouse, David Aaron Randolph, Harder, Nils-Peter, Rose, Douglas
• Primary Examiner(s): Ahmed, Selim
• Assistant Examiner(s): CLINTON, EVAN GARRETT
• Application Number:
  US15/283,251
• Publication Number:
  US 20180097125A1
• Time in Patent Office: 725 Days
• CPC Class Codes: H01L 24/78 Apparatus for connecting with wire connectors
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01L 31/0516 specially adapted for interconnection of back-contact solar cells
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H01L 31/188 Apparatus specially adapted for automatic interconnection of solar cells in a module
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Methods of fabricating a solar cell, and system for electrically coupling solar cells, are described. In an example, the methods for fabricating a solar cell can include placing conductive wires in a wire guide, where conductive wires are placed over a first semiconductor substrate having first doped regions and second doped regions. The method can include aligning the conductive wires over the first and second doped regions, where the wire guide aligns the conductive wires substantially parallel to the first and second doped regions. The method can include bonding the conductive wires to the first and second doped regions. The bonding can include applying a mechanical force to the semiconductor substrate via a roller or bonding head of the wire guide, where the wire guide inhibits lateral movement of the conductive wires during the bonding.

Claims

1. A method of fabricating a solar cell, the method comprising:

placing conductive wires in a wire guide, wherein the placing positions the conductive wires over a first semiconductor substrate having first doped regions and second doped regions, wherein placing conductive wires in the wire guide comprises placing conductive wires in a plurality of tubes;

aligning conductive wires over the first and second doped regions, wherein the wire guide aligns the conductive wires substantially parallel to the first and second doped regions to form a pairing of the semiconductor substrate and the conductive wires; and

bonding the conductive wires to the first and second doped regions by force to the pairing of the first semiconductor substrate and the conductive wires, wherein the mechanical force is applied via a roller, and wherein the wire guide inhibits lateral movement of the conductive wires during the bonding.

2. The method of claim 1, wherein placing conductive wires in the plurality of tubes comprises placing conductive wires having a diameter less than or equal to a diameter of the plurality of tubes.

3. The method of claim 1, wherein placing conductive wires in the plurality of tubes comprises placing conductive wires in a plurality of tubes having a half-tube extension.

4. The method of claim 1, wherein bonding the conductive wires to the first and second doped regions of a first substrate comprises performing thermocompression process or an ultrasonic bonding process.

5. The method of claim 1, further comprising:

aligning the conductive wires to first and second doped regions of a second semiconductor substrate, wherein the wire guide aligns the conductive wires substantially parallel to the first and second doped regions of the second semiconductor substrate to form a pairing of the second semiconductor substrate and the conductive wires; and

bonding the conductive wires to the first and second doped regions of the second semiconductor substrate by applying a mechanical force to the pairing of the first semiconductor substrate and the conductive wires, wherein the wire guide inhibits lateral movement of the conductive wires during the bonding.

6. The method of claim 1, wherein placing conductive wires into a wire guide comprises the placing conductive wires over a solar cell.

7. The method of claim 1, wherein aligning the conductive wires to first doped regions and second doped regions of a first substrate comprises aligning the conductive wires to n-type doped regions and p-type doped regions of a solar cell.

8. The method of claim 1 wherein aligning the conductive wires comprises positioning the conductive wires at approximately 12 degree angle from the first semiconductor substrate.

9. A method of fabricating a solar cell, the method comprising:

placing conductive wires in a wire guide, wherein the placing positions the conductive wires over a first semiconductor substrate having first doped regions and second doped regions;

aligning conductive wires over the first and second doped regions, wherein the wire guide aligns the conductive wires substantially parallel to the first and second doped regions to form a pairing of the semiconductor substrate and the conductive wires; and

bonding the conductive wires to the first and second doped regions by force to the pairing of the first semiconductor substrate and the conductive wires, wherein the mechanical force is applied via a roller, and wherein the wire guide inhibits lateral movement of the conductive wires during the bonding, wherein placing conductive wires in the wire guide comprises placing conductive wires in a plurality of closed grooves.

10. A method of fabricating a solar cell, the method comprising:

placing conductive wires in a wire guide, wherein the placing positions the conductive wires over a first semiconductor substrate having first doped regions and second doped regions, wherein the wire guide comprises a plurality of tubes or a plurality of closed grooves;

aligning conductive wires over the first and second doped regions, wherein the wire guide aligns the conductive wires substantially parallel to the first and second doped regions to form a pairing of the semiconductor substrate and the conductive wires; and

bonding the conductive wires to the first and second doped regions by applying a mechanical force to the pairing of the first semiconductor substrate and the conductive wires, wherein the mechanical force is applied via a bonding head of the wire guide, and wherein the wire guide inhibits lateral movement of the conductive wires during the bonding.

11. The method of claim 10, wherein applying a mechanical force to the pairing of the first semiconductor substrate and the conductive wires comprises applying a mechanical force to the pairing of the first semiconductor substrate and the conductive wires using a roller coupled to the bonding head of the wire guide.

12. The method of claim 10, wherein applying a mechanical force to pairing of the first semiconductor substrate and the conductive wires comprises applying an ultrasonic vibration to pairing of the first semiconductor substrate and the conductive wires.

13. The method of claim 10, further comprising:

aligning the conductive wires to first and second doped regions of a second semiconductor substrate, wherein a wire guide aligns the conductive wires substantially parallel to the first and second doped regions of the second semiconductor substrate to form a pairing of the semiconductor substrate and the conductive wires; and

bonding the conductive wires to the first and second doped regions by applying a mechanical force to the pairing of the second semiconductor substrate and the conductive wires, wherein the mechanical force is applied via a bonding head of the wired guide, wherein the wire guide inhibits lateral movement of the conductive wires during the bonding.

14. A system for electrically coupling solar cells, the system comprising:

a wire guide to align conductive wires substantially parallel with first and second doped regions of a first semiconductor substrate, wherein the wired guide comprises a plurality of tubes; and

a roller to bond the conductive wires to the first and second doped regions, wherein the wire guide inhibits lateral movement of the conductive wires in contact with the roller.

15. The system of claim 14, wherein the conductive wires have a diameter less than or equal to a diameter of the plurality of tubes.

16. The system of claim 14, wherein the plurality of tubes comprises a plurality of tubes having a half-tube extension.

18. The system of claim 14, wherein the roller is a heated roller.

17. A system for electrically coupling solar cells, the system comprising:

a wire guide to align conductive wires substantially parallel with first and second doped regions of a first semiconductor substrate; and

a roller to bond the conductive wires to the first and second doped regions, wherein the wire guide inhibits lateral movement of the conductive wires in contact with the roller, wherein the wire guide comprises a plurality of grooves to align conductive wires substantially parallel with first and second doped regions of a semiconductor substrate.