Fabrication Processes for Effectively Transparent Contacts

Abstract

In conventional solar cells with metal contacts, a non-negligible fraction of the incoming solar power is immediately lost either through absorption or reflection upon interaction with the contacts. Effectively transparent contacts (“ETCs”) for solar cells can be referred to as three-dimensional contacts designed to redirect incoming light onto a photoabsorbing surface of a solar cell. In many embodiments, the ETCs have triangular cross-sections. Such ETCs can be placed on a photoabsorbing surface such that at least one of their sides forms an angle with the photoabsorbing surface. In this configuration, the ETCs can redirect incident light onto the photoabsorbing surface, mitigating or eliminating reflection loss compared to conventional solar cells. When constructed in accordance with a number of embodiments of the invention, ETCs can be effectively transparent and highly conductive.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application is a continuation of U.S. application Ser. No. 15/999,264 entitled “Fabrication Processes for Effectively Transparent Contacts,” filed Aug. 17, 2018, which application claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/546,746 entitled “Fabrication Processes for Effectively Transparent Contacts,” filed Aug. 17, 2017. The disclosures of U.S. patent application Ser. No. 15/999,264 and U.S. Provisional Patent Application No. 62/546,746 are hereby incorporated by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under Grant No. DE-EE0004946/T-113750 awarded by the Department of Energy and Grant No. EEC1041895 awarded by the National Science Foundation. The government has certain rights in the invention.

FIELD OF THE INVENTION

The present invention generally relates to fabrication processes for contacts for solar cells and, more specifically, to effectively transparent contacts.

BACKGROUND

Photovoltaics refer to a class of methods for converting light into electricity using the photovoltaic effect. Due to technological advances in recent years, photovoltaics are becoming a more viable, carbon-free source of electricity generation. A photovoltaic system typically employs an array of solar cells to generate electrical power. Solar cells can be made of a variety of semiconductors, typically a silicon based structure, acting as a substrate and can include front and rear contacts that are used to conduct current out of the solar cell. The conversion process involves the absorption of light rays by what can be referred to as the active region of the solar cell, which can excite electrons in the substrate into a higher state of energy. The excitation allows the electrons to move as an electric current that can then be extracted to an external circuit and stored.

SUMMARY OF THE INVENTION

One embodiment includes a method for fabricating solar cells incorporating effectively transparent contacts, the method including providing a photoabsorbing surface, providing a mold stamp, wherein one of the surfaces of the mold stamp defines a plurality of grooves, and forming effectively transparent contacts on the photoabsorbing surface using the mold stamp.

In another embodiment, the photo-absorbing surface includes metal contacts, the plurality of grooves includes parallel grooves having a periodicity matching the periodicity of the metal contacts, and the effectively transparent contacts are formed on top of the metal contacts.

In a further embodiment, the effectively transparent contacts are formed by depositing conductive ink onto the metal contacts, placing the mold stamp in contact with the photosbsorbing surface such that the conductive ink fills the hollow channels formed by the plurality of grooves and the photoabsorbing surface, curing the conductive ink, and removing the mold stamp such that the cured conductive ink remains on the metal contacts.

In still another embodiment, the photo-absorbing surface includes metal contacts in a branching pattern, wherein the width of the metal contact reduces after each branching fork, the plurality of grooves includes grooves matching the pattern of the metal contacts, and the effectively transparent contacts are formed on top of the metal contacts.

In a still further embodiment, the effective transparent contacts are formed by filling the plurality of grooves with conductive ink, placing the mold stamp in contact with the photosbsorbing surface such that the side of the mold stamp with the filled plurality of grooves is adjacent with the photoabsorbing surface, curing the conductive ink, and removing the mold stamp such that the cured conductive ink remains on the photoabsorbing surface.

In yet another embodiment, the effective transparent contacts are formed by placing the mold stamp in contact with the photosbsorbing surface such that the side of the mold stamp with the plurality of grooves is adjacent with the photoabsorbing surface, filling the volume created by the plurality of grooves and the photoabsorbing surface with conductive ink, curing the conductive ink, and removing the mold stamp such that the cured conductive ink remains on the photoabsorbing surface.

In a yet further embodiment, forming the effectively transparent metal contacts further includes annealing the cured conductive ink after the removal of the mold stamp from the photoabsorbing surface.

In another additional embodiment, the plurality of grooves is filled with conductive ink using capillary action.

In a further additional embodiment, forming the effectively transparent contacts further includes performing a selective surface treatment on the mold stamp to render the inside of the plurality of grooves hydrophilic.

In another embodiment again, the plurality of grooves is filled with conductive ink using a combination of capillary action and a pressure system.

In a further embodiment again, the pressure system applies positive pressure to fill the plurality of grooves with the conductive ink.

In still yet another embodiment, the conductive ink includes a silver nanoparticle ink.

In a still yet further embodiment, the conductive ink further includes glass particles.

In still another additional embodiment, curing the silver nanoparticle ink includes a process selected from the group consisting of: thermal curing, ultraviolet radiation, electromagnetic radiation tuned to the nanoparticles in the silver nanoparticle ink, and applying a current.

In a still further additional embodiment, the mold stamp includes a material selected from the group consisting of polydimethylsiloxane, polymethyl methacrylate, and ethylene-vinyl acetate.

In still another embodiment again, the plurality of grooves includes parallel triangular grooves.

In a still further embodiment again, at least one of the plurality of grooves has a depth-to-width ratio of at least 2-to-1.

In yet another additional embodiment, the photoabsorbing surface includes a textured surface, the mold stamp is made of polydimethylsiloxane, wherein the polydimethylsiloxane is formulated such that the elasticity of the polydimethylsiloxane compensates for the textured surface of the absorbing surface to promote adhesion between the mold stamp and the photoabsorbing surface.

In a yet further additional embodiment, the effectively transparent contacts are formed in an environment having a temperature of less than 21° C.

In yet another embodiment again, the mold stamp includes a gravure-printing roll.

Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The description will be more fully understood with reference to the following figures and data graphs, which are presented as exemplary embodiments of the invention and should not be construed as a complete recitation of the scope of the invention.

FIG. 1 conceptually illustrates a profile view of a section of a solar cell with an effectively transparent contact on top of a standard planar contact in accordance with an embodiment of the invention.

FIG. 2 conceptually illustrates a top view of a solar cell with contacts in a leaf pattern in accordance with an embodiment of the invention.

FIG. 3 conceptually illustrates a manufacturing process for fabricating effectively transparent contacts utilizing a mold stamp in accordance with an embodiment of the invention.

FIGS. 4A and 4B conceptually illustrate the adhesion of a mold stamp to a textured surface of a solar cell in accordance with an embodiment of the invention.

FIG. 5 conceptually illustrates a mold stamp containing an inlet microfluidic channel for the deposition of conductive ink in accordance with an embodiment of the invention.

FIG. 6 conceptually illustrates a positive pressure system used to fill channels created from a mold stamp and a solar cell with a conductive ink in accordance with an embodiment of the invention.

FIGS. 7A-7C conceptually illustrate a process for fabricating ETCs on top of existing contacts of a solar cell in accordance with an embodiment of the invention.

FIGS. 8A and 8B conceptually illustrate a process for fabricating ETCs by filling a mold stamp with conductive ink prior to placement on a solar cell in accordance with an embodiment of the invention.

FIGS. 9A-9C conceptually illustrate a process for fabricating ETCs by depositing conductive ink directly onto contacts of a solar cell prior to placement of a mold stamp in accordance with an embodiment of the invention.

FIG. 10 conceptually illustrates a gravure printing process in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

Turning now to the drawings, solar cells incorporating effectively transparent contacts and methods for fabricating such structures in accordance with various embodiments of the invention are illustrated. In conventional solar cells with metal contacts, a non-negligible fraction of the incoming solar power is immediately lost either through absorption or reflection upon interaction with the contacts. Effectively transparent contacts (“ETCs”) for solar cells can be referred to as three-dimensional contacts designed to redirect incoming light onto a photoabsorbing surface of a solar cell. In many embodiments, the ETCs have triangular cross-sections. Such ETCs can be placed on a photoabsorbing surface such that at least one of their sides forms an angle with the photoabsorbing surface. In this configuration, the ETCs can redirect incident light onto the photoabsorbing surface, mitigating or eliminating reflection loss when compared to solar cells with conventional contacts. When constructed in accordance with a number of embodiments of the invention, ETCs can be effectively transparent and highly conductive. The contacts can also be incorporated within most types of solar cells.

Solar cells incorporating ETCs can be fabricated in many different ways, including through large-scale manufacturing techniques. In many embodiments, the ETCs are fabricated on top of existing contacts on solar cells. In other embodiments, the ETCs replace conventional contacts on the solar cells. Fabrication of ETCs can include the use of a mold stamp containing a plurality of grooves having cross-sections corresponding to the desired ETC shapes and dimensions. In several embodiments, the mold stamp is placed against a solar cell such that the side of the mold stamp containing the plurality of grooves is adhered to the solar cell. The mold stamp can be filled with a material from which the ETCs will be formed. The specific type of material used can depend on the specific application. In some embodiments, the mold stamp is filled with a conductive ink or paste, such as but not limited to silver nanoparticle ink. Many different types of filling methods can be implemented. Furthermore, the filling process can occur before or after the placement of the mold stamp against the solar cell. The material can then be cured and dislodged from the mold stamp, forming ETCs. Solar cells and methods of constructing solar cells incorporating ETCs in accordance with various embodiments of the invention are discussed further below.

Effective Transparency

In conventional solar cells with planar contacts, a non-negligible fraction of the incoming solar power is immediately lost either through absorption or through reflection. In such solar cells, only photons incident on the active photoabsorbing surface are capable of conversion to an electric current. Approaches for mitigating solar cell front contact losses can include using less absorbing transparent conductive oxides, or less reflective metal contacts. Achieving improved transparency using these approaches typically results in reduced conductivity, which in turn leads to series resistance electrical losses in the solar cell.

Solar cells in accordance with many embodiments of the invention incorporate effectively transparent contacts. The contacts are effectively transparent in the sense that they are formed with three-dimensional (“3D”) shapes that reflect or redirect incident photons onto the active photoabsorbing surface of the solar cell. ETCs can be implemented to overcome shadowing losses and parasitic absorption without significantly reducing the conductivity of the contacts relative to conventional planar grid fingers. A solar cell incorporating ETCs can be fabricated with the ETCs either on top of existing contacts or on the photoabsorbing surface. FIG. 1 conceptually illustrates a profile view of a section of a solar cell with an ETC on top of a standard planar contact in accordance with an embodiment of the invention. As shown, the solar cell 100 includes a planar contact 102 a triangular cross-section ETC 104 that is designed to redirect incident light 106 to an active photoabsorbing surface 108 of the solar cell. In this way, the triangular cross-section ETC can perform as effectively transparent.

Although triangular cross-section contacts are described above with reference to the solar cell illustrated in FIG. 1, any of a variety of ETCs having profiles that redirect incident radiation in a manner appropriate to the requirements of specific solar cell applications can be utilized in accordance with various embodiments of the invention. ETC designs and implementations are generally discussed in U.S. patent application Ser. No. 15/144,807, entitled “Solar Cells and Methods of Manufacturing Solar Cells Incorporating Effectively Transparent 3D Contacts,” and U.S. patent application Ser. No. 15/453,867, entitled “Encapsulated Solar Cells that Incorporate Structures that Totally Internally Reflect Light Away from Front Contacts and Related Manufacturing Methods.” The disclosures of U.S. patent application Ser. Nos. 15/144,807 and 15/453,867 are hereby incorporated by reference in their entireties.

Effectively Transparent Contact Designs

Effectively transparent contacts in accordance with various embodiments of the invention can be fabricated in a variety of shapes, sizes, and patterns. In certain embodiments, the triangular cross-sections can be equilateral triangles (having a base that is wider than the height of the triangle), isosceles triangles, right angle triangles, scalene triangles, or obtuse triangles. In various embodiments, the triangles are constructed to have heights that are greater than the base width of the triangles (i.e. the surface closest to the photoabsorbing surface has a width that is less than the height to which the triangle extends above the photoabsorbing surface). In many embodiments, a surface of the ETC has a parabolic shape. In other embodiments, any of a variety of surface shapes can be utilized that redirect light incident on the contacts onto the photoabsorbing surfaces of the solar cells.

ETCs can be fabricated with widely varying dimensions that can depend on the specific requirements of a given application. In many embodiments, the ETCs have triangular cross-sections with a height-to-base ratio of at least 2:1, where the base side sits parallel with respect to the surface of the solar cell. In further embodiments, the ETCs have a height-to-base ratio of at least 3:1. For example, in some embodiments, the ETCs are fabricated to be approximately 10 micrometers wide and approximately 30 micrometers high. As can readily be appreciated, the dimensions of the ETCs to be fabricated can depend on the specific requirements of a given application. Different fabrication processes can allow for different height-to-base ratios. Such differences in cross-sectional shapes and sizes can influence the effective transparency of the ETCs. Additionally, processes in accordance with various embodiments of the invention allow for the fabrication of ETCs having line widths of less than 10 micrometers.

A wide variety of ETC patterns can be implemented in accordance with various embodiments of the invention. In many embodiments, the ETCs are fabricated in a pattern that matches the pattern of existing contacts on a solar cell. In some embodiments, the ETCs are fabricated on the contact fingers of a solar cell in a parallel configuration of triangular prisms. ETCs can also be formed to have a tapered width and/or tapered height. By reducing the channel size, capillary forces can be enhanced. As will be discussed in the sections below, capillary forces can be used to aid the filling process in the fabrication of ETCs. In addition to enhancing the capillary forces, material use can be reduced. In a number of embodiments, an ETC having a triangular cross section is formed on the busbar of a solar cell. Busbar ETCs formed in accordance with various embodiments of the invention can have feature sizes of a few micrometers. Multiple triangular shaped busbars can be used to provide sufficient sheet resistance. In several embodiments, the sizes of the busbars are reduced to mesoscale in order to provide sufficient optical transparency and redirection of incoming light.

In a number of embodiments, the ETCs and existing contacts on the solar cell can be formed in a branching pattern. In further embodiments, the width of each groove or contact gets narrower as the branching gets deeper. Such a pattern can help facilitate the filling process through enhancement of capillary forces. In several embodiments, the branches are either perpendicular or parallel to one another. In other embodiments, the branching pattern is in a leaf pattern such that the branching angle can differ. In further embodiments, the branching angles are selected to enhance capillary forces. FIG. 2 conceptually illustrates a top view of a solar cell with contacts in a leaf pattern in accordance with an embodiment of the invention. As shown, the solar cell 200 includes a busbar 202 and a branching leaf pattern of fingers 204.

Although specific contact designs are discussed above, any of a variety of different contact shapes and patterns can be used to facilitate the redirection of incoming light and/or enhance the filling mechanisms, such as but not limited to increasing the capillary forces.

Fabrication Processes for Solar Cells Incorporating Effectively Transparent Contacts

Solar cells incorporating ETCs can be fabricated in many different ways in accordance with various embodiments of the invention. A solar cell can incorporate ETCs by either fabricating the ETCs on top of existing planar contacts or on top of the photoabsorbing surface of a solar cell. Many fabrication processes include the use of a mold stamp having grooves with cross-sections corresponding to the desired ETC structures to be fabricated. Mold stamps in accordance with various embodiments of the invention can be made of various materials, such as but not limited to polydimethylsiloxane (“PDMS”), polymethyl methacrylate (“PMMA”), ethylene-vinyl acetate (“EVA”), and other suitable polymers. In many embodiments, the mold stamp is formed as a copy of a master mold. The master mold can be formed using various microfabrication techniques. In some embodiments, additive manufacturing techniques are utilized at the micro-scale to form the desired structures on the master mold. In other embodiments, selective etching techniques, such as but not limited to dry etching, can be used to form the master mold. A mold stamp can then be formed as a relief from the master mold using standard molding techniques.

In embodiments where the ETCs are fabricated on top of existing contacts, the fabrication process is introduced as a secondary metallization step in the overall fabrication process of the manufacturing of the solar cell. The secondary step can be integrated with existing processes for the manufacturing of solar cells. In a conventional solar cell, metal contacts can form an ohmic contact with the semiconductor metal below the contact. Once these contacts are formed, the secondary metallization step can be introduced to integrate aligned ETCs on top of the existing metal contacts to mitigate shading losses and improve electrical conductivity.

A manufacturing process for fabricating ETCs utilizing a mold stamp in accordance with an embodiment of the invention is conceptually illustrated in FIG. 3. The process 300 can include providing (302) a solar cell. In many embodiments, the solar cell contains existing planar contacts. Solar cells can be fabricated using conventional techniques known in the art. A mold stamp can be provided (304). Mold stamps in accordance with various embodiments of the invention can contain a pattern of grooves. In embodiments where the solar cell contains planar contacts, the grooves can be designed to have a periodicity that matches the periodicity of the existing planar contacts. Any of a number of methods for fabricating mold stamps, such as those described above, can be utilized.

The mold stamp can then be placed (306) onto the solar cell. In embodiments where the solar cell contains existing contacts, the mold stamp can be placed such that the grooves line up and are in contact with the planar contacts, forming a channel above each planar contact within which the conductive ink can fill. In many embodiments, the material of the mold stamp and the surface of the solar cell are adequate to promote sufficient adhesion such that the conductive ink would not leak out of the formed channels. In some embodiments, pressure can be applied to hold the mold stamp and solar cell together. In further embodiments, a clamping mechanism can be used to hold the mold stamp and solar cell together. Depending on the elasticity of the mold stamp and the structural integrity of the solar cell, the pressure can be adjusted accordingly to prevent damaging the solar cell.

In many embodiments, the solar cell contains a textured surface. In such embodiments, the mold stamp can be fabricated to have an elasticity and softness that help the stamp adhere to the textured surface. For example, the elasticity and softness of PDMS mold stamps can be adjusted during the fabrication process by adjusting the PDMS base to curing agent ratio. In a number of embodiments, the PDMS formulations include base to curing agent weight ratios ranging from 5:1 to 25:1. As can readily be appreciated, the specific base to curing agent weight ratio utilized can depend on the degree of the textured surface of the solar cell. Typically, more textured surfaces can require softer mold stamps. In some embodiments, the textured surface contains features with peak-to-peak distances of at least two micrometers. In such embodiments, a 25:1 base to curing agent ratio of PDMS can be used to form a soft mold stamp that can adhere to the textured surface.

FIGS. 4A and 4B conceptually illustrate a mold stamp adhered to a textured surface of a solar cell in accordance with an embodiment of the invention. As shown, the solar cell 400 contains a textured surface 402. A PDMS mold stamp 404 can be formulated with a high elasticity such that adhesion to the textured surface 402 can be achieved.

The formed channels can be filled (308) with the conductive ink. Many different types of conductive ink can be used to form ETCs in accordance with various embodiments of the invention. In many embodiments, silver nanoparticle ink is used to form the ETCs. In some embodiments, glass particles are added to the conductive ink mixture. In embodiments where the ETCs are formed on top of planar contacts, the glass particles within the conductive ink mixture can help promote adequate adhesion between the ETCs and the existing contacts.

Various methods can be applied to ensure that the conductive ink fills the channel as desired. In many embodiments, the small feature sizes of the channels allow for the channels to be filled with the conductive ink through capillary forces. In a number of embodiments, the mold stamp is tilted and gravity is used to fill the grooves with conductive ink. In several embodiments, the mold stamp contains at least one through-hole connected with the grooves through which the channels can be filled with conductive ink. FIG. 5 conceptually illustrates such a mold stamp. As shown, the mold stamp 500 includes an inlet microchannel 502 for ink deposition. In some embodiments, a pressure system is used to facilitate the infilling and/or enhance the capillary forces. The pressure provided by such an external system can be applied individually to each channel to promote homogeneous pressure profiles. The other side of the mold stamp can be opened to remove air from the channels. Either positive or negative pressure systems can be used for such processes. For example, in several embodiments, a vacuum system is used to facilitate the infilling.

FIG. 6 conceptually illustrates a positive pressure system used to fill channels created from a mold stamp and a solar cell with a conductive ink in accordance with an embodiment of the invention. As shown, the system 600 contains an ink reservoir/positive pressure system 602 capable of filling channels 604 formed by a mold stamp 606 and a solar cell 608. The ink reservoir/positive pressure system 602 injects ink in one side of the channels as air escapes out the opposite side.

In many embodiments, a selective surface treatment is performed on the mold stamp to change the surface energy of the treated surfaces. Such treatment can be performed to render the inside of the channel hydrophilic, which can enhance the capillary action. Surface treatments can include but are not limited to oxygen plasma treatment and isopropyl alcohol treatment.

The environmental conditions can affect whether the infilling process is successful. For example, by lowering the relative humidity, the capillary action can be boosted. As such, in many embodiments, the channels are filled in an environment with a relative humidity level of less than 20%. In some embodiments, the temperature of the environment is adjusted to enhance the capillary action. In further embodiments, the filling process takes place in an environment that is below room temperature, or below 21° C. Such conditions can be regulated by performing the process in a glove box where the conditions are more easily controlled. As can readily be appreciated, the specific environmental conditions can depend on the specific type of conductive ink utilized.

After the channels are adequately filled, the conductive ink can be cured (310). In many cases, the conductive ink is cured by removing solvents within the mixture. Depending on the type of conductive ink used, one or more appropriate curing processes are utilized. For example, curing processes for conductive ink containing nanoparticles can include but are not limited to electromagnetic radiation of a certain wavelength that is resonant with the nanoparticles, creating heat. Other curing processes can include but are not limited to the application of heat, ultraviolet radiation, and the application of a current. The degree of these curing processes can also depend on the specific conductive ink used. In some embodiments, thermal curing is performed on the conductive ink at temperatures of at least 100° C. in order to remove the solvents within the conductive ink.

After the curing process, the mold stamp can be removed (312), leaving behind the cured conductive ink, or formed ETCs, on top of the planar contacts. The formed ETCs can optionally be annealed (314) to reduce the individual ETCs gridline resistance. In many embodiments, the annealing step is performed at a higher temperature than a typically thermal curing process in accordance with various embodiments of the invention.

FIGS. 7A-7C conceptually illustrate a process for fabricating ETCs on top of existing contacts of a solar cell in accordance with an embodiment of the invention. As shown, the process includes utilizing an alignment system 700 for aligning and placing a mold stamp 702 on top of a solar cell 704 having existing planar contacts 706. Once placed, the mold stamp 702 forms channels 708 with the solar cell 704, which are then filled using a microfluidic dispenser 710 (FIG. 7B). A heater 712 is used to heat the solar cell 704, which applies thermal energy to the adjacent conductive ink in order to remove solvents from the ink. The mold stamp 702 is then removed, leaving behind ETCs 714 (FIG. 7C).

Although FIGS. 3 and 7A-7C illustrate a specific class of processes for fabricating ETCs, any of a number of different methods can be utilized. For example, in many embodiments, the grooves of a mold stamp are filled with a conductive ink before the stamp is placed against the solar cell. The filling process can include any of the processes described above, such as but not limited to the use of capillary forces. In some embodiments, a dispensing system is utilized to fill the grooves. The dispensing system can include one or more nozzles configured to deposit the conductive ink. In further embodiments, each individual nozzle is configured to contemporaneously move along and infill over the length of a groove. In several embodiments, the dispensing system is stationary while the mold stamp travels. In other embodiments, the dispensing system continuously deposits the conductive ink at a certain point along the length of the groove until the groove is filled. As the system deposits the ink, capillary action can cause the deposited ink to fill the length of the groove. In further embodiments, the mold stamp is made of an elastomer material and can be stretched, bent, and/or twisted to alter the cross-sectional shape of the grooves. Such contortions of the shape can facilitate the infilling process.

FIGS. 8A and 8B conceptually illustrate a process for fabricating ETCs by filling a mold stamp with conductive ink prior to placement on a solar cell in accordance with an embodiment of the invention. As shown, a system of ink nozzles 800 is used to fill a mold stamp 802 with conductive ink. FIG. 8B shows that a solar cell 804 can then be placed above the mold stamp 802 such that the conductive ink is in contact with the solar cell 804. A curing process can then be applied, and the mold stamp 802 can be removed to leave behind formed ETCs.

Another class of processes for fabricating ETCs includes a direct deposition step. In such embodiments, conductive ink can be deposited directly onto the planar contacts. Given the typical scale of the ETC structures, only a small amount of conductive ink is usually required to be deposited. In many embodiments, the conductive ink is deposited as micro-droplets onto the busbar of the solar cell. In other embodiments, the conductive ink is deposited next to the active area of the solar cell. A mold stamp can then be aligned and placed against the solar cell with the groove side against the existing contacts. The grooves can trap the conductive ink micro-droplets, and capillary forces can cause the ink to fill the channels formed by the grooves and existing contacts. In a number of embodiments, the process includes moving the mold stamp to form ETCs across a large area. In several embodiments, multiple mold stamps are used to form ETCs across a large area. The fabrication process can then proceed similarly as the processes described above.

In some embodiments, surface functionalization can be performed on the solar cells such that the ink accumulates at a desired position. For example, the contact grid can be treated to be hydrophilic while the areas in between are configured to be hydrophobic. In further embodiments, vibrations can be applied to the solar cell to aid movement of ink droplets to the desired areas. In a number of embodiments, gas pressure, such as but not limited to the use of an inert gas, can be used to blow any ink droplets to a desired state.

FIGS. 9A-9C conceptually illustrate a process for fabricating ETCs by depositing conductive ink directly onto contacts of a solar cell prior to placement of a mold stamp in accordance with an embodiment of the invention. FIG. 9A shows a top view of a solar cell 900 having a busbar 902 and contact fingers 904. Micro-droplets of conductive ink 906 can be deposited on the busbar 902 (FIG. 9B). A mold stamp can then be placed against the solar cell 900. Through the mechanisms such as those described above, the deposited ink fills the channels created by the mold stamp. Once a curing process is applied and the mold stamp is removed, a pattern of conductive ink 908 remains on top of the busbar 902 and contact fingers 904.

In some embodiments, a sacrificial layer is applied onto the solar cell. ETCs can be deposited using any of the methods mentioned above. In such embodiments, selective filling of the mold stamp within the grooves is not needed as the sacrificial layer can be etched away to remove residues between the ETCs.

In many embodiments, a gravure printing process is utilized to form ETCs. In such embodiments, the mold stamp is essentially a gravure-printing roll. The roll can include grooves with dimensions corresponding to the desired dimensions of the ETCs to be formed. In a number of embodiments, the grooves are spaced to match existing contacts on the solar cell. During the fabrication process, the grooves can be filled or selectively filled with conductive ink, such as but not limited to silver nanoparticle ink. Filling mechanisms such as those described above can be applied. For example, conductive ink can be deposited onto a small local area of a groove on the gravure-printing roll. Once the gravure printing roll moves across the solar cell, the small cross sections created by the grooves and existing contacts can cause capillary forces to facilitate the infilling of the channels. Alternatively, the conductive ink can be deposited onto the existing contacts of the solar cell. In some embodiments, the solar cell is heated such that when the ink-filled grooves come into contact with the surface of the solar cell, solvent within the ink can be removed. Thus, the ink will be deposited as the gravure printing roll rolls across the solar cell. In several embodiments, the gravure-printing roll can be heated to facilitate the solvent removal process to allow for better deposition. In some embodiments, ultraviolet-curing ink is used. As the gravure printing roll moves over the solar cell, ultraviolet light can be used to cure the ink such that the ink will be deposited onto the solar cell.

FIG. 10 conceptually illustrates a gravure printing process in accordance with an embodiment of the invention. As shown, the process 1000 utilizes a gravure-printing roll 902 and a dispensing nozzle 1004 to form a pattern of ETCs 1006 on a solar cell 1008. As the gravure printing roll 1002 rolls across the solar cell 1008, the dispensing nozzle 1004 is configured to fill in one or more of the grooves 1010 of the gravure-printing roll 1002. Contemporaneously, using a curing mechanism such as those described above, the conductive ink within a filled groove can be deposited onto the solar cell 1008 to form an ETC 1006.

While the above description contains many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as an example of one embodiment thereof. It is therefore to be understood that the present invention may be practiced in ways other than specifically described, without departing from the scope and spirit of the present invention. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents.

Claims

1. A method for fabricating solar cells incorporating effectively transparent contacts, the method comprising:

providing a photoabsorbing surface;

providing a mold stamp, wherein one of the surfaces of the mold stamp defines a plurality of grooves; and

forming effectively transparent contacts on the photoabsorbing surface using the mold stamp.

2. The method of claim 1, wherein:

the photo-absorbing surface comprises metal contacts;

the plurality of grooves comprises parallel grooves having a periodicity matching the periodicity of the metal contacts; and

the effectively transparent contacts are formed on top of the metal contacts.

3. The method of claim 2, wherein the effectively transparent contacts are formed by:

depositing conductive ink onto the metal contacts;

placing the mold stamp in contact with the photosbsorbing surface such that the conductive ink fills the hollow channels formed by the plurality of grooves and the photoabsorbing surface;

curing the conductive ink; and

removing the mold stamp such that the cured conductive ink remains on the metal contacts.

4. The method of claim 1, wherein:

the photo-absorbing surface comprises metal contacts in a branching pattern, wherein the width of the metal contact reduces after each branching fork;

the plurality of grooves comprises grooves matching the pattern of the metal contacts; and

the effectively transparent contacts are formed on top of the metal contacts.

5. The method of claim 1, wherein the effective transparent contacts are formed by:

filling the plurality of grooves with conductive ink;

placing the mold stamp in contact with the photosbsorbing surface such that the side of the mold stamp with the filled plurality of grooves is adjacent with the photoabsorbing surface;

curing the conductive ink; and

removing the mold stamp such that the cured conductive ink remains on the photoabsorbing surface.

6. The method of claim 1, wherein the effective transparent contacts are formed by:

placing the mold stamp in contact with the photosbsorbing surface such that the side of the mold stamp with the plurality of grooves is adjacent with the photoabsorbing surface;

filling the volume created by the plurality of grooves and the photoabsorbing surface with conductive ink;

curing the conductive ink; and

removing the mold stamp such that the cured conductive ink remains on the photoabsorbing surface.

7. The method of claim 6, wherein forming the effectively transparent metal contacts further comprises annealing the cured conductive ink after the removal of the mold stamp from the photoabsorbing surface.

8. The method of claim 6, wherein the plurality of grooves is filled with conductive ink using capillary action.

9. The method of claim 6, wherein forming the effectively transparent contacts further comprises performing a selective surface treatment on the mold stamp to render the inside of the plurality of grooves hydrophilic.

10. The method of claim 6, wherein the plurality of grooves is filled with conductive ink using a combination of capillary action and a pressure system.

11. The method of claim 10, wherein the pressure system applies positive pressure to fill the plurality of grooves with the conductive ink.

12. The method of claim 6, wherein the conductive ink comprises a silver nanoparticle ink.

13. The method of claim 12, wherein the conductive ink further comprises glass particles.

14. The method of claim 12, wherein curing the silver nanoparticle ink comprises a process selected from the group consisting of: thermal curing, ultraviolet radiation, electromagnetic radiation tuned to the nanoparticles in the silver nanoparticle ink, and applying a current.

15. The method of claim 1, wherein the mold stamp comprises a material selected from the group consisting of polydimethylsiloxane, polymethyl methacrylate, and ethylene-vinyl acetate.

16. The method of claim 1, wherein the plurality of grooves comprises parallel triangular grooves.

17. The method of claim 16, wherein at least one of the plurality of grooves has a depth-to-width ratio of at least 2-to-1.

18. The method of claim 1, wherein:

the photoabsorbing surface comprises a textured surface;

the mold stamp is made of polydimethylsiloxane, wherein the polydimethylsiloxane is formulated such that the elasticity of the polydimethylsiloxane compensates for the textured surface of the absorbing surface to promote adhesion between the mold stamp and the photoabsorbing surface.

19. The method of claim 1, wherein the effectively transparent contacts are formed in an environment having a temperature of less than 21° C.

20. The method of claim 1, wherein the mold stamp comprises a gravure printing roll.