System and Method for Forming Solar Cell Structures

A partially processed semiconductor substrate for manufacturing a solar cell, the substrate comprises:

• a support layer, the support layer being characterized by a thickness of at least 150 microns;
• an adhesive layer overlaying the support layer;
• a photovoltaic material overlaying the transferring layer, the photovoltaic material being characterized by a thickness of less than fifteen microns, the photovoltaic material including a top region and a bottom region, the top region being characterized by a first impurity type, the bottom side being characterized by a second impurity type, the first impurity type and the second impurity type having opposite polarities, the photovoltaic material including a first opening, the first opening exposing the bottom region;
• a passivation overlaying the photovoltaic material, the passivation including a second opening exposing the top region;
• an anti-reflection region overlaying the passivation, the anti-reflection region including a third opening exposing the top region;
• a first metal contact including a first portion and a second portion, the first portion being electrically coupled to the bottom region, and second portion being partially overlaying the anti-reflection region;
• and
• a second metal contact including a third portion and a fourth portion, the third portion being electrically coupled to the top region, the fourth portion being partially overlaying the anti-reflection region.

A method for manufacturing a solar cell, the method comprising:

• providing a partially processed semiconductor substrate, the substrate including at least a support layer and a photovoltaic material, the support layer being characterized by a thickness of at least 150 microns, the photovoltaic material overlaying the support layer, the photovoltaic material being characterized by a thickness of less than fifteen microns, the photovoltaic material including a top region and a bottom region, the top region being characterized by a first polarity, the bottom side being characterized by a second polarity, the first polarity being opposite from the second polarity;
• forming a mask overlaying the top side, the mask exposing at least a first contact region;
• forming a first contact opening partially exposing the bottom side;
• removing the mask;
• forming a passivation overlaying the top region;
• forming an anti-reflection coating overlaying the passivation;
• defining a pattern using the anti-reflection region for the first opening and a second opening, the second opening being positioned outside the first contact region and exposing the a portion of the top region;
• and
• sputtering metal material to form a first metal contact and a second metal contact using a sputtering process, the first metal contact being electrically coupled to the top region, the second metal contact being electrically coupled to the bottom region, the first metal contact and the second metal contact being positioned on a same side.

A method for manufacturing a solar cell, the method comprising:

• providing a substrate, the substrate including a support region;
• transferring a photovoltaic material overlying the support region of the substrate, the photovoltaic material being characterized by a first thickness, the photovoltaic material including a conducting layer positioned within the first thickness;
• forming an emitter region on the photovoltaic material by a at least diffusion process, the emitter region being characterized by a first impurity type;
• forming a mask overlaying the emitter region, the mask exposing at least a first contact region;
• forming the first contact region within the first thickness of the photovoltaic material;
• doping the first contact region with a second impurity type, the second impurity type and the first impurity type being characterized by opposite polarities;
• removing the mask;
• forming a passivation overlaying the first contact region and the photovoltaic;
• forming an anti-reflection coating overlaying the passivation;
• defining a plurality of contact positions, the plurality of contact positions including a first contact position and a second contact position;
• depositing a silver paste material over the plurality of contact positions;
• subjecting the silver paste material to a first condition (temperature, etc);
• and
• forming a first contact and a second contact using the silver paste material, the first contact being electrically coupled to the contact region, the second contact being electrically coupled to the emitter region.