Metallization of solar cells using metal foils
AssigneeSunPower Corporation
InventorThomas PASS
Life of this patent
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Abstract
A solar cell structure includes P-type and N-type doped regions. A dielectric spacer is formed on a surface of the solar cell structure. A metal layer is formed on the dielectric spacer and on the surface of the solar cell structure that is exposed by the dielectric spacer. A metal foil is placed on the metal layer. A laser beam is used to weld the metal foil to the metal layer. A laser beam is also used to pattern the metal foil. The laser beam ablates portions of the metal foil and the metal layer that are over the dielectric spacer. The laser ablation of the metal foil cuts the metal foil into separate P-type and N-type metal fingers.
Claims20
A method of fabricating a solar cell, the method comprising:
- forming a dielectric spacer on a surface of a solar cell structure;
- forming a metal layer on the dielectric spacer, an N-type doped region, and a P-type doped region, wherein the metal layer electrically connects the N-type doped region to the P-type doped region;
- placing a metal foil on the metal layer;
- and
- after placing the metal foil on the metal layer, patterning the metal foil, wherein patterning the metal foil includes removing portions of the metal foil and the metal layer that are over the dielectric spacer.
A solar cell structure comprising:
- an N-type doped region and a P-type doped region;
- a dielectric spacer over the N-type doped region and the P-type doped region;
- a first metal layer over the dielectric spacer and the N-type doped region, wherein the first metal layer is electrically connected to the N-type doped region;
- a second metal layer over the dielectric spacer and the P-type doped region, wherein the second metal layer is electrically connected to the P-type doped region;
- a first metal foil finger that is electrically bonded to the first metal layer;
- and
- a second metal foil finger that is electrically bonded to the second metal layer.
A method of fabricating a solar cell, the method comprising:
- forming a dielectric spacer on a surface of a solar cell structure;
- depositing a metal layer on portions of the surface of the solar cell structure that are exposed by the dielectric spacer;
- fitting a metal foil to the metal layer;
- and
- patterning the metal foil after fitting the metal foil to the metal layer.
Dependencies are inferred from the claim text.