Methods for electroless plating of a solar cell metallization layer
AssigneeSunPower Corporation
InventorsMichael Cudzinovic, Joseph Behnke
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Abstract
A method for forming a contact region for a solar cell is disclosed. The method includes depositing a paste composed of a first metal above a substrate of the solar cell, curing the paste to form a first metal layer, electrolessly plating a second metal layer on the first metal layer and electrolytically plating a third metal layer on the second metal layer, where the second metal layer electrically couples the first metal layer to the third metal layer. The method can further include electrolytically plating a fourth metal layer on the third metal layer.
Claims20
A method for forming a contact region for a solar cell, the solar cell having a front side which faces the sun during normal operation, and a back side opposite the front side, the method comprising:
- depositing a paste comprising a first metal above a substrate of the solar cell;
- curing the paste to form a first metal layer;
- electrolessly plating a second metal layer on the first metal layer;
- and
- electrolytically plating a third metal layer on the second metal layer, wherein the second metal layer electrically couples the first metal layer to the third metal layer.
A method for forming a contact region for a solar cell, the solar cell having a front side which faces the sun during normal operation, and a back side opposite the front side, the method comprising:
- depositing, in an interdigitated pattern, an aluminum paste above a substrate of the solar cell;
- curing the aluminum paste to form a layer of aluminum;
- electrolessly plating a second metal layer with a thickness of at least 0.1 microns on the layer of aluminum;
- electrolytically plating a third metal layer on the second metal layer, wherein the second metal layer electrically couples the layer of aluminum to the third metal layer;
- and
- electrolytically plating a fourth metal layer on the third metal layer.
A method for forming a contact region for a solar cell, the solar cell having a front side which faces the sun during normal operation, and a back side opposite the front side, the method comprising:
- depositing, in an interdigitated pattern, an aluminum paste with a thickness of at least 0.5 microns above a substrate of the solar cell;
- thermally curing the aluminum paste to form a layer of aluminum;
- electrolessly plating a second metal layer comprising a barrier metal with a thickness of at least 0.1 microns on the layer of aluminum, wherein the barrier metal is adapted to prevent diffusion of metals into the substrate;
- electrolytically plating a third metal layer on the second metal layer, wherein the second metal layer electrically couples the layer of aluminum to the third metal layer;
- and
- electrolytically plating a fourth metal layer on the third metal layer.
Dependencies are inferred from the claim text.