Module fabrication of solar cells with low resistivity electrodes

• US 10,115,839 B2
• Filed: 07/27/2016
• Issued: 10/30/2018
• Est. Priority Date: 01/11/2013
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Heng, Jiunn Benjamin, Fu, Jianming, Xu, Zheng, Yang, Bobby
• Primary Examiner(s): Leong, Susan D
• Application Number:
  US15/221,200
• Publication Number:
  US 20160351727A1
• Time in Patent Office: 825 Days
• CPC Class Codes: H01L 31/0201 comprising specially adapted module bus-bar structures
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01L 31/0684 double emitter cells, e.g. bifacial solar cells
• CPC Class Codes: H01L 31/0747 comprising a heterojunction of crystalline and amorphous materials, e.g. heterojunction with intrinsic thin layer
• CPC Class Codes: H02S 40/30 Electrical components
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• CPC Class Codes: Y02E 10/547 Monocrystalline silicon PV cells

Abstract

One embodiment of the present invention provides a solar module. The solar module includes a front-side cover, a back-side cover, and a plurality of solar cells situated between the front- and back-side covers. A respective solar cell includes a multi-layer semiconductor structure, a front-side electrode situated above the multi-layer semiconductor structure, and a back-side electrode situated below the multi-layer semiconductor structure. Each of the front-side and the back-side electrodes comprises a metal grid. A respective metal grid comprises a plurality of finger lines and a single busbar coupled to the finger lines. The single busbar is configured to collect current from the finger lines.

Claims

1. A solar module, comprising:

a first solar cell having a first back-side emitter layer, and having only an area along one edge on a back-side surface covered by a first busbar; and

a second solar cell having only an area along one edge on a front-side surface covered by a second busbar;

wherein the first solar cell and second solar cell are coupled by overlapping the first busbar and second busbar.

2. The solar module of claim 1, wherein the first solar cell has a front surface-field layer.

3. The solar module of claim 1, wherein each of the first and second solar cells has a set of finger lines on a respective surface and coupled to the corresponding busbar.

4. The solar module of claim 1, a respective busbar of each of the first and second solar cells comprises plated Cu.

5. The solar module of claim 1, wherein the first and second busbars are soldered together.

6. The solar module of claim 1, wherein each of the first and second solar cells is a bi-facial solar cell.

7. The solar module of claim 1, further comprising a front-side cover and back-side cover, wherein the first and second solar cells are positions between the front-side and back-side covers.

8. The solar module of claim 7, wherein the first and second solar cells are laminated with a sealant material between the front-side and back-side covers.

9. The solar module of claim 1, further comprising additional solar cells, wherein two adjacent solar cells are coupled together by overlapping edges of the two adjacent solar cells, wherein the two adjacent solar cells are overlapped in such a way that a front-side edge busbar of one respective solar cell is coupled to a back-side edge busbar of an adjacent solar cell, thereby facilitating a serial connection between the two adjacent solar cells.

10. The solar module of claim 9, wherein a plurality of solar cells are coupled by overlapping edges to form a string, and wherein a plurality of strings are coupled electrically in series or in parallel.

11. The solar module of claim 1, wherein each of the first and second solar cells has a multi-layer semiconductor structure that includes a quantum tunneling barrier layer.

12. The solar module of claim 1, wherein a width of a respective busbar is between 0.5 and 3 mm.

13. The solar module of claim 1, further comprising a plurality of maximum power point tracking (MPPT) devices, wherein a respective MPPT device is coupled to an individual solar cell, thereby facilitating cell-level MPPT.

14. The solar module of claim 1, further comprising a plurality of MPPT devices, wherein a respective MPPT device is coupled to a string of solar cells, thereby facilitating string-level MPPT.

15. The solar module of claim 1, further comprising transparent front-side and the back-side covers, thereby facilitating bifacial operation of the solar module.

16. A solar cell coupling system, comprising:

a first solar cell and a second solar cell, wherein a respective solar cell comprises a back-side emitter layer, a front-side electrode, and a back-side electrode, and wherein a respective electrode comprises a busbar;

wherein the first solar cell'"'"'s back-side surface has only an area along one edge covered by a first busbar;

wherein the second solar cell'"'"'s front-side surface has only an area along one edge covered by a second busbar; and

wherein the first busbar and second busbar are overlapped and in physical contact, thereby facilitating coupling between the first and second solar cells.

17. The solar cell coupling system of claim 16, wherein each electrode comprises a set of finger lines;

and

a respective busbar comprises plated Cu.

18. A solar cell coupling system, comprising:

a first busbar positioned on a back-side surface of a first solar cell; and

a second busbar positioned on a front-side surface of a second solar cell;

wherein the first busbar and second busbar are physically attached to each other in an overlapping manner;

wherein the first solar cell has only an area along one edge on the back-side surface covered by the first busbar;

wherein the second solar cell has only an area along one edge on the front-side surface covered by the second busbar; and

wherein each of the first and second solar cells has a back-side emitter layer.

19. The solar cell coupling system of claim 18, further comprising:

a layer of soldering material between the first and second busbars.

20. The solar cell coupling system of claim 18, wherein each of the first and second busbars comprises plated Cu.