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;
- 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.
A method of fabricating a solar cell, the method comprising:
- forming a dielectric spacer over an interface of adjacent P-type and N-type doped regions a solar cell structure;
- forming a metal layer over the dielectric spacer;
- fitting a metal foil to the metal layer;
- and
- patterning the metal foil in a first laser process after fitting the metal foil to the metal layer.
A method of fabricating a solar cell, the method comprising:
- forming a dielectric spacer over a surface of a solar cell structure;
- forming a metal layer over the dielectric spacer;
- fitting a metal foil to the metal layer;
- patterning the metal foil in a laser ablation process after fitting the metal foil to the metal layer;
- and
- welding the metal foil to the metal layer in a laser welding process.
Dependencies are inferred from the claim text.