Abstract: Embodiments of the invention contemplate formation of a high efficiency solar cell utilizing an adjustable or optimized laser patterning process to form openings with different geometry in a passivation layer disposed on a substrate based on different film properties in the passivation layer and the substrate. In one embodiment, a method of forming a solar cell includes transferring a substrate having a passivation layer formed on a back surface of a substrate into a laser patterning apparatus, performing a substrate inspection process by a detector disposed in the laser patterning apparatus, determining a laser patterning recipe configured to form openings in the passivation layer based on information obtained from the substrate inspection process, and performing a laser patterning process on the passivation layer using the determined laser patterning recipe.

Abstract: Embodiments of the present invention generally provide methods for forming features or holes in a passivation layer without damaging the underlying solar cell substrate. A source laser beam is split into a first laser beam and a second laser beam. The first laser beam is modified to have a different wavelength than the source laser beam. The second laser beam is delayed for a predetermined time, and the first and second laser beams are delivered to a surface of the substrate.

Abstract: Embodiments of the invention contemplate formation of a high efficiency solar cell utilizing a laser patterning process to form openings in a passivation layer while maintaining good film properties of the passivation layer on a surface of a solar cell substrate. In one embodiment, a method of forming an opening in a passivation layer on a back surface of a solar cell substrate includes transferring a substrate having a passivation layer formed on a back surface of a substrate into a laser patterning apparatus, the substrate having a first type of doping atom on the back surface of the substrate and a second type of doping atom on a front surface of the substrate, providing laser radiation generated by the laser patterning apparatus from the front surface transmitting through the substrate to the passivation layer disposed on the back surface of the substrate, and forming openings in the passivation layer.

Abstract: Embodiments of the invention relate to methods for fabricating a passivation layer stack for photovoltaic devices. In one embodiment, the passivation layer stack comprises a first dielectric layer of AlxOy (or SiOx) and a second dielectric layer of SixNy having a refractive index less than 2.1. The passivation layer stack has contact openings formed therethrough by a series of pulsed laser beams having a wavelength of about 300-700 nm and a pulse width of about 0.01 nanosecond to about 3 nanoseconds. Lowering the refractive index of SixNy capping AlxOy (or SiOx) in the passivation layer stack makes pulsed laser beams less selective since the SixNy absorbs less laser energy. Therefore, desired regions of the entire passivation layer stack can be removed smoothly in a single pass of pulsed laser beams at a shorter wavelength without causing damage to the neighborhood of the passivation layer stack.

Abstract: Embodiments of the invention contemplate the formation of a high efficiency solar cell using a laser patterning process to form openings in a passivation layer on a surface of a solar cell substrate. In one embodiment, a method of forming an opening in a passivation layer on a solar cell substrate includes forming a passivation layer on a back surface of a substrate, the substrate having a first type of doping atom on the back surface of the substrate and a second type of doping atom on a front surface of the substrate, and providing a series of laser pulses to the passivation layer for between about 500 picoseconds and about 80 nanoseconds to form openings in the passivation layer.

Abstract: A laser scanning apparatus that uses a polygonal mirror and a beam shaper for laser drilling of holes in one or more layers during solar cell fabrication is provided. The apparatus may be used to laser drill holes in a back side passivation layer of a solar cell during back electrical contact formation. The apparatus includes the use of a polygonal mirror to improve the speed of the back electrical formation of a solar cell. The apparatus may also include the use of a beam shaper to tune the profile of the beam to prevent damage to the underlying solar cell substrate during laser drilling operations. A laser scanning module is provided which controls the speed and timing of linear movement of substrates and the operation of the laser scanning apparatus in a closed loop manner for laser drilling of material layers disposed on the substrates.

Abstract: Methods and systems for manufacturing back contact solar cells that have improved efficiency and device electrical properties. the solar cell device described herein includes an Emitter Wrap Through (EWT) solar cell that has plurality of laser drilled vias disposed in a spaced apart relationship to metal gridlines formed on a surface of the substrate. Solar cell structures that may benefit from the invention disclosed herein include back-contact solar cells, such as those in which both positive and negative contacts are formed only on the rear surface of the device.

Abstract: The invention is directed to a multi-adjustable paint applicator assembly including an elongated handle with a first adjustment assembly that provides angular movement of an upper handle portion with respect to a lower handle portion. A base is rotatably connected to the handle by a second adjustment assembly that provides rotational movement of the base with respect to the handle. The base also has an upper portion with a receiver that slidingly engages a projection extending from a paint applicator. The paint applicator may be a paint brush, roller or pad with an applicator surface. The first and second adjustment assemblies each include a fastener and an arrangement of mating members that intermesh with another arrangement of mating members, wherein the fastener provides tension between the arrangements to releasably secure the angular or rotational position.