Thin film solar cell structure

• US 9,716,194 B2
• Filed: 12/12/2014
• Issued: 07/25/2017
• Est. Priority Date: 05/01/2012
• Status: Active Grant

• Current Assignee: Chihhua Yang
• Original Assignee: Chihhua Yang
• Inventors: Yang, Chihhua
• Primary Examiner(s): Dinh, Bach
• Application Number:
  US14/568,696
• Publication Number:
  US 20150096614A1
• Time in Patent Office: 956 Days
• Field of Search: 136243-265
• CPC Class Codes: H01L 31/02366 of the substrate or of a layer on the substrate, e.g. textured ITO/glass substrate or superstrate, textured polymer layer on glass substrate
• CPC Class Codes: H01L 31/03529 Shape of the potential jump barrier or surface barrier
• CPC Class Codes: H01L 31/0547 comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
• CPC Class Codes: H01L 31/056 the light-reflecting means being of the back surface reflector [BSR] type
• CPC Class Codes: Y02E 10/52 PV systems with concentrators

Abstract

A thin film solar cell includes a protection layer, a substrate and a photovoltaic conversion structure having a stack of one or several of non-planar light absorption layers, a first conductive layer being light transmissive and a second conductive layer being at least partially transparent or totally reflective. When the second conductive layer is totally reflective, it reflects the sunlight to the adjacent part of the thin film solar cell, proceeding another photovoltaic conversion and generating electric power again. If the non-planar light absorption layer is sloped enough, there will be several photovoltaic conversions produced by the same incident sunlight. More power will be generated and the efficiency of conversion is increased. If the second conductive layer is at least partially transparent, the incident light will be reflected less. However, the structure will provide several opportunities of photovoltaic conversions for the light with larger incident angle.

Claims

1. A thin film solar cell structure, comprising:

at least one non-planar light absorption layer having a first face and a second face opposite to the first face;

a light transmissive first conductive layer arranged on the first face of the light absorption layer; and

a second conductive layer arranged under the second face of the light absorption layer;

wherein the non-planar light absorption layer has peaks and valleys, at least one peak of the non-planar light absorption layer having a first upper portion on the first face and a first lower portion on the second face, at least one valley of the non-planar light absorption layer having a second upper portion on the first face and a second lower portion on the second face, the lower portion of one peak being higher than the upper portion of one valley adjacent to the peak, a vertical distance between the first lower portion of one peak and the second lower portion of one valley adjacent to the peak is at least ten times of a thickness of the light absorption layer, the thickness of the light absorption layer being defined by the distance between the first upper portion and the first lower portion of one peak or the distance between the second upper portion and the second lower portion of one valley, the first conductive layer has uneven undulation substantially along with the light absorption layer;

wherein the non-planar light absorption layer has a relatively flat portion on the second face thereof and the relatively flat portion having slope smaller than 50 degree to a horizontal plane,

wherein both the peak and the valley of the non-planar light absorption layer have the relatively flat portion;

wherein a ratio of a total sum of a horizontal projection of the relatively flat portion including in both of the peak and the valley of the non-planar light absorption layer to a horizontal projection of the whole light absorption layer is less than 25%, wherein the horizontal projection is a projected portion to an artificial plane on which a substrate of the thin film solar cell structure is placed;

wherein a series-connecting area between any two neighbor thin film solar cells has a wasted area incapable of generating electrical power, the wasted area having a thickness, a length in the direction of the series connection and perpendicular to the direction of the thickness and an effective width in undulation on a substrate, the thickness of the wasted area being defined by the accumulated thickness of the first conductive layer, the light absorption layer and the second conductive layer at one peak or at one valley.

2. The thin film solar cell structure in claim 1, wherein the second conductive layer has a reflection rate larger than 20%.

3. The thin film solar cell structure in claim 1, wherein the light absorption layer has non-planar structures with undulated vertical cross-section along at least one dimension, the slope of the non-planar light absorption layer has a substantially fixed angle of 60 or 75 degree with respect to a horizontal plane.

4. The thin film solar cell structure in claim 1, wherein the light absorption layer has non-planar structures with undulated vertical cross-section along at least one dimension, the slope of the non-planar light absorption layer has a varying angle to a horizontal plane with position.

5. The thin film solar cell structure in claim 1,

wherein the non-planar light absorption layer has peaks and valleys, at least one peak of the non-planar light absorption layer having a first upper portion on the first face and a first lower portion on the second face, at least one valley of the non-planar light absorption layer having a second upper portion on the first face and a second lower portion on the second face, the lower portion of one peak being higher than the upper portion of one valley adjacent to the peak, a vertical distance between the first lower portion of one peak and the second lower portion of one valley adjacent to the peak is at least ½

of the distance in the length direction of the wasted area, the thickness of the light absorption layer being defined by the distance between the first upper portion and the first lower portion of one peak or the distance between the second upper portion and the second lower portion of one valley, the first conductive layer has uneven undulation substantially along with the light absorption layer.

6. The thin film solar cell structure in claim 1,

wherein the wasted area has a pattern varies in the direction of the length with its position on the thin film solar cell structure instead of lying on a plane perpendicular to the direction of the length.

7. The thin film solar cell structure in claim 1,

wherein the wasted area has a first interface to the first thin film solar cell and a second interface to the second thin film solar cell on the other side, in addition to share the undulation with the light absorption layer, the first interface also undulates in the length direction along with the location in the undulation, the second interface also undulate in the length direction along with the location in the undulation.

8. The thin film solar cell structure in claim 1, wherein the horizontal projection of the relatively flat portion on the valley has no more area than the horizontal projection of the relatively flat portion on the peak does.

9. A thin film solar cell structure, comprising:

at least one non-planar light absorption layer having a first face and a second face opposite to the first face;

a light transmissive first conductive layer arranged on the first face of the light absorption layer; and

a second conductive layer arranged under the second face of the light absorption layer;

wherein the non-planar light absorption layer has peaks and valleys, at least one peak of the non-planar light absorption layer having a first upper portion on the first face and a first lower portion on the second face, at least one valley of the non-planar light absorption layer having a second upper portion on the first face and a second lower portion on the second face, the lower portion of one peak being higher than the upper portion of one valley adjacent to the peak, a vertical distance between the first lower portion of one peak and the second lower portion of one valley adjacent to the peak is at least ten times of a thickness of the light absorption layer, the thickness of the light absorption layer being defined by the distance between the first upper portion and the first lower portion of one peak or the distance between the second upper portion and the second lower portion of one valley, the first conductive layer has uneven undulation substantially along with the light absorption layer;

wherein the non-planar light absorption layer has a relatively flat portion on the second face thereof and the relatively flat portion having slope smaller than 60 degree to a horizontal plane,

wherein both the peak and the valley of the non-planar light absorption layer have the relatively flat portion;

wherein a ratio of a total sum of a horizontal projection of the relatively flat portion including in both of the peak and the valley of the non-planar light absorption layer to a horizontal projection of the whole light absorption layer is less than 50%, wherein the horizontal projection is a projected portion to an artificial plane on which a substrate of the thin film solar cell structure is placed;

wherein a series-connecting area between any two neighbor thin film solar cells has a wasted area incapable of generating electrical power, the wasted area having a thickness, a length in the direction of the series connection and perpendicular to the direction of the thickness and an effective width in undulation on a substrate, the thickness of the wasted area being defined by the accumulated thickness of the first conductive layer, the light absorption layer and the second conductive layer at one peak or at one valley.

10. The thin film solar cell structure in claim 9, wherein the second conductive layer has a reflection rate larger than 20%.

11. The thin film solar cell structure in claim 9, wherein the light absorption layer has non-planar structures with undulated vertical cross-section along at least one dimension, the slope of the non-planar light absorption layer has a substantially fixed angle of 60 or 75 degree with respect to a horizontal plane.

12. The thin film solar cell structure in claim 9, wherein the light absorption layer has non-planar structures with undulated vertical cross-section along at least one dimension, the slope of the non-planar light absorption layer has a varying angle to a horizontal plane with position.

13. The thin film solar cell structure in claim 9, wherein the non-planar light absorption layer has peaks and valleys, at least one peak of the non-planar light absorption layer having a first upper portion on the first face and a first lower portion on the second face, at least one valley of the non-planar light absorption layer having a second upper portion on the first face and a second lower portion on the second face, the lower portion of one peak being higher than the upper portion of one valley adjacent to the peak, a vertical distance between the first lower portion of one peak and the second lower portion of one valley adjacent to the peak is at least 1/2 of the distance in the length direction of the wasted area, the thickness of the light absorption layer being defined by the distance between the first upper portion and the first lower portion of one peak or the distance between the second upper portion and the second lower portion of one valley, the first conductive layer has uneven undulation substantially along with the light absorption layer.

14. The thin film solar cell structure in claim 9, wherein the wasted area has a pattern varies in the direction of the length with its position on the thin film solar cell structure instead of lying on a plane perpendicular to the direction of the length.

15. The thin film solar cell structure in claim 9, wherein the wasted area has a first interface to the first thin film solar cell and a second interface to the second thin film solar cell on the other side, in addition to share the undulation with the light absorption layer, the first interface also undulates in the length direction along with the location in the undulation, the second interface also undulate in the length direction along with the location in the undulation.

16. The thin film solar cell structure in claim 9, wherein the horizontal projection of the relatively flat portion on the valley has no more area than the horizontal projection of the relatively flat portion on the peak does.