SOLAR CELL, SOLAR CELL MODULE USING SOLAR CELL, AND MANUFACTURING METHOD FOR SOLAR CELL

• US 20120291844A1
• Filed: 07/30/2012
• Published: 11/22/2012
• Est. Priority Date: 03/19/2010
• Status: Active Grant

• Current Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Original Assignee: C/O Sanyo Electric Company Limited
• Inventors: TSUGE, Sadaji
• Granted Patent: US 9,299,871 B2
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: H01L 31/022425 for solar cells
• CPC Class Codes: H01L 31/022433 Particular geometry of the grid contacts
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• 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 30/10 Frame structures
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

The present invention is to grant a margin in the control of a depth of a groove when removing a transparent insulation layer after the transparent insulation layer is formed on the entire surface of the transparent conductive layer, thereby provide a solar cell which has superior productivity in mass manufacturing. A solar cell includes an n-type amorphous silicon layer formed on a front-surface side of an n-type monocrystalline silicon the substrate; a front-surface side transparent conductive layer formed on the n-type amorphous silicon layer; a p-type amorphous silicon layer formed on a rear-surface-side of the substrate; and a rear-surface-side transparent conductive layer formed on the p-type amorphous silicon layer. A front-surface side collector electrode is formed by plating on the front-surface side transparent conductive layer whereas a rear-surface-side collector electrode is formed on the rear-surface-side transparent conductive layer by printing.

Claims

1. A solar cell comprising:

a crystalline semiconductor substrate of a first conductivity type;

a first amorphous semiconductor layer of the first conductivity type formed on a first surface of the crystalline semiconductor substrate;

a first collector electrode formed on the first amorphous semiconductor layer;

a second amorphous semiconductor layer of a second conductivity type formed on a second surface of the crystalline semiconductor substrate; and

a second collector electrode formed on the second amorphous semiconductor layer;

wherein

the first collector electrode is formed by plating,

the second collector electrode being formed by a method not impairing a junction between the crystalline semiconductor substrate and the second amorphous semiconductor layer,

the first collector electrode covering a smaller area than the second collector electrode.

2. The solar cell according to claim 1, wherein a transparent conductive layer and a transparent insulation layer are formed in this order on the first amorphous semiconductor layer,

the first collector electrode being formed with including a groove made in the transparent insulation layer.

3. The solar cell according to claim 1, further comprising a transparent conductive layer on the second amorphous semiconductor layer,

wherein a region in the transparent conductive layer formed with the second collector electrode has the same surface profile as of the other regions in the transparent conductive layer.

4. The solar cell according to claim 1, wherein the second collector electrode is formed by printing method or vapor deposition method.

5. The solar cell according to claim 1, wherein the second collector electrode is formed by plating method on an entire surface of the second amorphous semiconductor layer.

6. The solar cell according to claim 1, wherein the first collector electrode is placed on a light receiving side.

7. A solar cell comprising:

a crystalline semiconductor substrate of a first conductivity type;

a first amorphous semiconductor layer of the first conductivity type formed on a first surface of the crystalline semiconductor substrate;

a first collector electrode formed on the first amorphous semiconductor layer;

a second amorphous semiconductor layer of a second conductivity type formed on a second surface of the crystalline semiconductor substrate; and

a second collector electrode formed on the second amorphous semiconductor layer;

wherein

a transparent conductive layer and a transparent insulation layer are formed in this order on the first amorphous semiconductor layer,

the first collector electrode being formed with including a groove made in the transparent insulation layer,

the second amorphous semiconductor layer being formed with a transparent conductive layer thereon,

the second collector electrode being formed on a surface of the second transparent conductive layer,

a region in the transparent conductive layer formed with the second collector electrode having the same surface profile as of the other regions in the transparent conductive layer.

8. A solar cell module comprising a plurality of solar cells sealed between a front surface member and a rear surface member, wherein

the solar cell comprising:

a crystalline semiconductor substrate of a first conductivity type;

a first amorphous semiconductor layer of the first conductivity type formed on a first surface of the crystalline semiconductor substrate;

a first collector electrode formed on the first amorphous semiconductor layer;

a second amorphous semiconductor layer of a second conductivity type formed on a second surface of the crystalline semiconductor substrate; and

a second collector electrode formed on the second amorphous semiconductor layer;

wherein

a transparent conductive layer and a transparent insulation layer are formed in this order on the first amorphous semiconductor layer,

the first collector electrode being formed with including a groove made in the transparent insulation layer,

the second amorphous semiconductor layer being formed with a transparent conductive layer thereon,

the second collector electrode being formed on a surface of the second transparent conductive layer,

a region in the transparent conductive layer formed with the second collector electrode having the same surface profile as of the other regions in the transparent conductive layer,

the first collector electrode having a surface facing the front surface member,

the second collector electrode having a surface facing the rear surface member.

9. The solar cell module according to claim 8, further comprising a terminal box disposed on a surface of the rear surface member.

10. A method for manufacturing a solar cell, comprising:

forming an amorphous semiconductor layer of one conductivity type on a front-surface side of a crystalline semiconductor substrate of said conductivity type and forming an amorphous semiconductor layer of another conductivity type on a rear-surface side thereof;

forming a transparent conductive layer on each of the amorphous semiconductor layers;

forming a transparent insulation layer on the front-surface side transparent conductive layer;

forming an open groove which reaches the transparent conductive layer by selectively removing the transparent insulation layer;

forming a front-surface side collector electrode in the open groove by plating;

forming a rear-surface-side collector electrode on the rear-surface-side transparent conductive layer by printing method or vapor deposition method.

11. The method for manufacturing the solar cell according to claim 10, wherein the opening is formed by laser.