SOLAR CELL OR TANDEM SOLAR CELL AND METHOD OF FORMING SAME

• US 20140352751A1
• Filed: 05/31/2013
• Published: 12/04/2014
• Est. Priority Date: 05/31/2013
• Status: Abandoned Application

• Current Assignee: TSMC Solar Ltd. (Taiwan Semiconductor Manufacturing Company Limited)
• Original Assignee: TSMC Solar Ltd. (Taiwan Semiconductor Manufacturing Company Limited)
• Inventors: WU, Chung-Hsien, XU, Wei-Lun, CHEN, Shih-Wei, YEN, Wen-Tsai, XU, Li
• Application Number:
  US13/906,932
• Publication Number:
  US 20140352751A1
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: H01L 31/03928 including AIBIIICVI compound, e.g. CIS, CIGS deposited on metal or polymer foils
• CPC Class Codes: H01L 31/043 Mechanically stacked PV cells
• CPC Class Codes: H01L 31/0725 Multiple junction or tandem solar cells
• CPC Class Codes: H01L 31/0749 including a AIBIIICVI compound, e.g. CdS/CulnSe2 [CIS] heterojunction solar cells
• CPC Class Codes: H01L 31/1892 methods involving the use of temporary, removable substrates
• CPC Class Codes: Y02E 10/541 CuInSe2 material PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A solar cell includes an absorber layer, a buffer layer on the absorber layer, a front contact layer where a glass substrate, a back contact layer on the glass substrate, the absorber layer on the back contact layer, the buffer layer, and the front contact layer are manufactured as a first module at a temperature exceeding 500 degrees Celsius. The solar further includes an extracted portion from the first module where the extracted portion includes the absorber layer, the buffer layer, and the front contact layer, and where the extracted portion is applied to a flexible substrate or other substrate.

Claims

1. A solar cell, comprising:

an absorber layer;

a buffer layer on the absorber layer;

a front contact layer, wherein a glass substrate, a back contact layer on the glass substrate, the absorber layer on the back contact layer, the buffer layer, and the front contact layer are manufactured as a first module at a temperature exceeding 500 degrees Celsius;

an extracted portion from the first module, the extracted portion comprising the absorber layer, the buffer layer, and the front contact layer; and

a flexible substrate or other substrate, wherein the extracted portion is applied to the flexible substrate or other substrate.

2. The solar cell of claim 1, wherein the extracted portion is applied to the flexible substrate or other substrate at a temperature below 500 degree Celsius.

3. The solar cell of claim 1, wherein the extracted portion is applied to a metal layer and the flexible substrate or other substrate.

4. The solar cell of claim 1, wherein the extracted portion is applied to a conductive polymer layer and the flexible substrate or other substrate.

5. The solar cell of claim 1, wherein the flexible substrate or other substrate is a interconnect layer that interconnects the extracted portion to a second front contact layer of a second module comprising a second glass substrate, a second back contact layer, a second absorber layer, a second buffer layer, and the second front contact layer.

6. The solar cell of claim 5, wherein the extracted portion and the second module form a tandem solar cell.

7. The solar cell of claim 6, wherein the second module is one of a silicon solar cell, a dye-sensitized solar cell, an organic solar cell, or a copper indium, gallium, selenium (CIGS) solar cell.

8. The solar cell of claim 1, comprising a conductive bus applied to the front contact layer and a transparent tape or an organic glue or a transparent conductive tape placed on at least portions of a top of the front contact layer and the conductive bus.

9. The solar cell of claim 1, wherein the absorber layer comprises copper, indium, gallium, and selenium.

10. The solar cell of claim 1, wherein the glass substrate comprises soda lime glass, the back contact layer comprises molybdenum, the absorber layer comprises copper, indium, gallium, and selenium, the buffer layer comprises one of cadmium sulfide or zinc sulfide, and the front contact layer comprises one of aluminum-doped zinc oxide, boron-doped zinc oxide, or indium tin oxide.

11. The solar cell of claim 1, comprising a transparent conductive tape or organic glue used to separate the extracted portion from the glass substrate and the back contact layer.

12. The solar cell of claim 1, comprising a first scribed portion through the back contact layer, a second scribed portion through the absorber layer, and a third scribed portion through the back contact layer, the absorber layer, and the front contact layer.

13. The solar cell of claim 1, wherein the flexible substrate or the other substrate is a different shape from the glass substrate.

14. A method of making a solar cell, comprising

forming a back contact layer on a glass substrate;

forming an absorber layer on the back contact layer;

forming a buffer layer on the absorber layer;

forming a front contact layer above the buffer layer, the glass substrate, the back contact layer, the absorber layer, the buffer layer, and the front contact layer forming a first module;

extracting from the first module an extracted portion comprising the absorber layer, the buffer layer, and the front contact layer; and

applying the extracted portion above a flexible substrate or other substrate.

15. The solar cell of claim 14, wherein the first module is manufactured at a temperature exceeding 500 degrees Celsius.

16. A method of making a solar cell of claim 14, wherein the flexible substrate or other substrate is an interconnect layer connecting the extracted portion to a second module, and wherein the method further comprises:

forming a second back contact layer on a second glass substrate;

forming an second absorber layer on the second back contact layer;

forming a second buffer layer on the second absorber layer;

forming a second front contact layer above the second buffer layer, wherein the second glass substrate, the second back contact layer, the second absorber layer, the second buffer layer, and the second front contact layer form the second module; and

forming the interconnect layer between the extracted portion and the second contact layer of the second module.

17. The method of claim 14, wherein the extracting comprises delaminating or tearing the extracted portion from the back contact layer and the glass substrate.

18. The method of claim 14, further comprising forming transparent conductive tape or organic glue on the front contact layer.

19. The method of claim 14, further comprising scribing a first scribed portion through the back contact layer, scribing a second scribed portion through the absorber layer, and scribing a third scribed portion through the back contact layer, the absorber layer, and the front contact layer.

20. A method of making a solar cell, comprising

forming a back contact layer on a glass substrate by sputtering molybdenum on the glass substrate;

forming an absorber layer on the back contact layer by sputtering or co-evaporating combination s of copper, indium, gallium, and selenium on the back contact layer;

forming a buffer layer on the absorber layer by chemical bath deposition of cadmium sulfide or zinc sulfide on the absorber layer;

forming a front contact layer above the buffer layer, wherein the glass substrate, the back contact layer, the absorber layer, the buffer layer, and the front contact layer form a first module formed at temperatures exceeding 500 degrees Celsius;

transferring or delaminating from the first module an extracted portion comprising the absorber layer, the buffer layer, and the front contact layer; and

applying the extracted portion above a flexible substrate or other substrate.