Solar cell structure utilizing an amorphous silicon discrete by-pass diode

• US 6,784,358 B2
• Filed: 11/08/2002
• Issued: 08/31/2004
• Est. Priority Date: 11/08/2002
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kukulka, Jerry R.
• Primary Examiner(s): DIAMOND, ALAN D
• Application Number:
  US10/291,350
• Publication Number:
  US 20040089338A1
• Time in Patent Office: 662 Days
• Field of Search: 136/256, 136/258, 136/261, 136/252, 136/255, 136/249, 136/244
• US Class Current: 136/244
• CPC Class Codes: H01L 27/142 Energy conversion devices photovoltaic modules or arrays of single photovoltaic cells comprising bypass diodes integrated or directly associated with the devices H01L31/0443; photovoltaic modules composed of a plurality of thin film solar cells deposited on the same substrate H01L31/046
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A solar cell structure includes a solar cell that produces a voltage when illuminated, and a discrete amorphous silicon by-pass diode. A first by-pass diode terminal of the amorphous silicon by-pass diode is electrically connected to a first side of an active semiconductor structure of the solar cell, and a second by-pass diode terminal of the amorphous silicon by-pass diode is electrically connected to a second side of the active semiconductor structure. Alternatively, the first by-pass diode terminal of the amorphous silicon by-pass diode may be electrically connected to the first side of the active semiconductor structure of the solar cell, and the second by-pass diode terminal of the amorphous silicon by-pass diode may be electrically connected to a second side of the active semiconductor structure of another solar cell.

Claims

1. A solar cell structure comprising:

a solar cell comprising an active semiconductor structure having a first active semiconductor structure side and a second active semiconductor structure side, wherein the solar cell produces a voltage between the first active semiconductor structure side and the second active semiconductor structure side when illuminated; and

a by-pass diode structure, wherein the by-pass diode structure comprises

a discrete amorphous silicon by-pass diode, wherein the by-pass diode has a first by-pass diode terminal and a second by-pass diode terminal,

a first electrical diode interconnection in electrical communication between the first active semiconductor structure side and the first by-pass diode terminal, and

a second electrical diode interconnection in electrical communication between the second active semiconductor structure side and the second by-pass diode terminal.

2. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side.

3. The solar cell structure of claim 1, wherein

the first electrical diode interconnection comprises a first-active-semiconductor-structure-side metallization in contact with the first active semiconductor structure side and with the first by-pass diode terminal, and wherein

the by-pass diode is supported on the first-active-semiconductor-structure-side metallization.

4. The solar cell structure of claim 1, wherein the solar cell further comprises

an electrically semiconductive substrate having a first substrate side comprising

a contacting substrate portion that contacts the second active semiconductor structure side, and

a noncontacting substrate portion that does not contact the second active semiconductor structure side,

wherein the second electrical diode interconnection is in electrical communication with the noncontacting substrate portion.

5. The solar cell structure of claim 1, wherein the solar cell structure further comprises

an electrically semiconductive substrate having a first substrate side comprising

a contacting substrate portion that contacts the second active semiconductor structure side, and

a noncontacting substrate portion that does not contact the second active semiconductor structure side,

wherein the second electrical diode interconnection comprises a second-interconnection lead extending between the noncontacting substrate portion and the second by-pass diode terminal.

6. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side, and

a back-side metallization in contact with the second substrate side,

wherein

the first electrical diode interconnection comprises a first-active-semiconductor-structure-side metallization in contact with the first-active-semiconductor-structure-side metallization and with the first by-pass diode terminal, and

the second electrical diode interconnection is in electrical communication between the back-side metallization and the second by-pass diode terminal.

7. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side, and

a back-side metallization in contact with the second substrate side,

wherein

the first electrical diode interconnection comprises a first-active-semiconductor-structure-side metallization in contact with the first-active-semiconductor-structure-side metallization and with the first by-pass diode terminal, and

the second electrical diode interconnection comprises a second-interconnection lead extending between the back-side metallization and the second by-pass diode terminal.

8. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side, and

a back-side metallization in contact with the second substrate side,

and wherein

the by-pass diode is supported on the back-side metallization.

9. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side,

wherein

the first electrical diode interconnection comprises a first-active-semiconductor-structure-side metallization contacting the first active semiconductor structure side and in electrical communication with the first by-pass diode terminal, and

the second electrical diode interconnection comprises a back-side metallization in contact with the second substrate side and with the second by-pass diode terminal.

10. The solar cell structure of claim 1, wherein the solar cell further comprises

a substrate having a first substrate side in contact with the second active semiconductor structure side and a second substrate side oppositely disposed to the first substrate side,

wherein

the first electrical diode interconnection comprises

a first-active-semiconductor-structure-side metallization contacting the first active semiconductor structure side, and

a first-interconnection lead extending between the first-active-semiconductor-structure-side metallization and the first by-pass diode terminal, and

the second electrical diode interconnection comprises a back-side metallization in contact with the second substrate side and with the second by-pass diode terminal.

15. The solar cell structure of claim 1, wherein the by-pass diode is about 2-3 micrometers thick.

11. A solar cell structure comprising:

a first solar cell comprising

a first-cell active semiconductor structure having a first-cell first active semiconductor structure side and a first-cell second active semiconductor structure side, wherein the solar cell produces a voltage between the first-cell first active semiconductor structure side and the first-cell second active semiconductor structure side when illuminated;

a second solar cell comprising

a second-cell active semiconductor structure having a second-cell first active semiconductor structure side and a second-cell second active semiconductor structure side, wherein the solar cell produces a voltage between the second-cell first active semiconductor structure side and the second-cell second active semiconductor structure side when illuminated; and

a by-pass diode structure, wherein the by-pass diode structure comprises

a discrete amorphous silicon by-pass diode, wherein the by-pass diode has a first by-pass diode terminal and a second by-pass diode terminal,

a first electrical diode interconnection in electrical communication between the first-cell first active semiconductor structure side and the first by-pass diode terminal, and

a second electrical diode interconnection in electrical communication between the second-cell second active semiconductor structure side and the second by-pass diode terminal.

12. The solar cell structure of claim 11, wherein the first electrical diode interconnection comprises

a first-cell first-active-semiconductor-structure-side metallization in contact with the first-cell first active semiconductor structure side and with the first by-pass diode terminal.

13. The solar cell structure of claim 11, wherein the second electrical diode interconnection comprises a second-interconnection lead.

14. The solar cell structure of claim 11, wherein the second electrical diode interconnection comprises

a second-cell substrate having a second-cell first substrate side in contact with the second-cell second active semiconductor structure side, and an oppositely disposed second-cell second substrate side,

a second-cell back-side metallization in contact with the second-cell second substrate side, and

a second-interconnection lead extending between the second-cell back-side metallization and the second by-pass diode terminal.

16. A solar cell structure comprising:

a solar cell comprising an active semiconductor structure having a first active semiconductor structure side and a second active semiconductor structure side, wherein the solar cell produces a voltage between the first active semiconductor structure side and the second active semiconductor structure side when illuminated; and

a by-pass diode structure, wherein the by-pass diode structure comprises

an amorphous silicon by-pass diode, wherein the by-pass diode exists separately from the solar cell, wherein a structure of the by-pass diode is not integral with a structure of the solar cell, and wherein the by-pass diode has a first by-pass diode terminal and a second by-pass diode terminal,

a first electrical diode interconnection in electrical communication between the first active semiconductor structure side and the first by-pass diode terminal, and

a second electrical diode interconnection in electrical communication between the second active semiconductor structure side and the second by-pass diode terminal.