Solar cell with structured gridline endpoints and vertices
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B05D-005/12
H01L-031/00
출원번호
US-0873473
(2010-09-01)
등록번호
US-8586129
(2013-11-19)
발명자
/ 주소
Fork, David K.
Solberg, Scott E.
출원인 / 주소
Solarworld Innovations GmbH
인용정보
피인용 횟수 :
0인용 특허 :
38
초록▼
A micro-extrusion printhead assembly utilized in a micro-extrusion system to form parallel extruded lines of material on a substrate includes a material feed mechanism for pushing/drawing materials out of dispensing orifices defined in the printhead assembly, a Z-axis positioning mechanism, and a ba
A micro-extrusion printhead assembly utilized in a micro-extrusion system to form parallel extruded lines of material on a substrate includes a material feed mechanism for pushing/drawing materials out of dispensing orifices defined in the printhead assembly, a Z-axis positioning mechanism, and a base. A production method utilizes the micro-extrusion system to directly print endpoint structures at the end of each gridline, and by extruding these gridlines immediately after forming the busbars. In accordance with an embodiment of the invention, the micro-extrusion system is controlled to manipulate the printhead speed and/or gridline material extrusion pressure at the beginning, middle and end of each gridline printing process such that teardrop-shaped endpoint structures are formed at the ends of each gridline, whereby each endpoint structure has a substantially greater width than that of the main “central” gridline structure extending between the endpoint structures.
대표청구항▼
1. A method for producing an H-pattern solar cell structure including a plurality of parallel gridlines on an upper surface of a target substrate using a micro-extrusion system, the micro-extrusion system including: an extrusion printhead assembly,a material feed mechanism for controllably supplying
1. A method for producing an H-pattern solar cell structure including a plurality of parallel gridlines on an upper surface of a target substrate using a micro-extrusion system, the micro-extrusion system including: an extrusion printhead assembly,a material feed mechanism for controllably supplying gridline material to said extrusion printhead assembly such that said gridline material is selectively forced from a plurality of dispensing orifices of said extrusion printhead assembly, and a transport mechanism for supporting the extrusion printhead assembly and said target substrate, and for moving the extrusion printhead assembly relative to said target substrate such that said gridline material exiting said plurality of dispensing orifices forms said plurality of parallel gridlines on the upper surface of the target substrate,wherein the method comprises:during a first time period, causing said material feed mechanism to force said gridline material through said plurality of dispensing orifices while causing said transport mechanism to move said extrusion printhead assembly relative to said target substrate such that first endpoint structures are formed on said target substrate adjacent to a first side edge of said target substrate, wherein each said first endpoint structure has a nominal first width; andduring a second time period following the first time period, causing said material feed system to force said gridline material through said plurality of dispensing orifices while causing said transport mechanism to move said extrusion printhead assembly relative to said target substrate such that central gridline portions are formed that extend across the target substrate, wherein each said central gridline portion is integrally connected to an associated one of said first endpoint structures and has a nominal second width that is smaller than the nominal first width,further comprising, during a third time period following the second time period, causing said material feed system to force said gridline material through said plurality of dispensing orifices while causing said transport mechanism to move said extrusion printhead assembly relative to said target substrate such that second endpoint structures are formed on said target substrate adjacent to a second side edge of said target substrate, wherein said second endpoint structures is integrally connected to an associated one of said central gridline portions and has a third nominal width that is greater than the second nominal width before said first time period, forming one or more busbars on said target substrate; and during said second time period, causing said material feed system to force said gridline material through said plurality of dispensing orifices while causing said transport mechanism to move said extrusion printhead assembly relative to said target substrate such that said central gridline portions include vertex portions that extend across the one or more busbars. 2. The method according to claim 1, wherein said method comprises causing said material feed system to force said gridline material through said plurality of dispensing orifices at a higher pressure during said first and third time periods than during said second time period. 3. The method according to claim 2, wherein said method comprises: causing said material feed system to force said gridline material through said plurality of dispensing orifices at a first pressure during said first time period, causing said material feed system to force said gridline material through said plurality of dispensing orifices at a second pressure during said second time period, said second pressure being lower than said first pressure, and causing said material feed system to force said gridline material through said plurality of dispensing orifices at a third pressure during said third time period, said third pressure being higher than said second pressure. 4. The method according to claim 3, wherein the first pressure is equal to the third pressure. 5. The method according to claim 1, wherein said method comprises causing said transport mechanism to move said extrusion printhead assembly over said target substrate at a slower speed during said first and third time periods than during said second time period. 6. The method according to claim 5, wherein said method comprises: causing said transport mechanism to move said extrusion printhead assembly over said target substrate at a first speed during said first time period, causing said transport mechanism to move said extrusion printhead assembly over said target substrate at a second speed during said second time period, said second speed being faster than said first speed, and causing said transport mechanism to move said extrusion printhead assembly over said target substrate at a third speed during said third time period, said third speed being slower than said second speed. 7. The method according to claim 6, wherein the first speed is equal to the third speed. 8. The method according to claim 1, further comprising: before the first time period, causing said transport means to move said extrusion printhead assembly to a first point disposed over said target substrate and adjacent to the first side edge of said target substrate while causing said material feed system to prevent flow of said gridline material through said plurality of dispensing orifices; and after the third time period, causing said transport means to move said extrusion printhead assembly away from said target substrate while causing said material feed system to prevent flow of said gridline material through said plurality of dispensing orifices. 9. The method according to claim 1, wherein said extrusion printhead assembly includes a first inlet port and a second inlet port, a plurality of central channels that communicate between said first inlet port and an associated merge point region, and a plurality of side channels that communicate between said second inlet port and said associated merge point regions, each said associated merge point regions communicating with one of said plurality of dispensing orifices, and wherein said method comprises, during said second time period, causing said material feed mechanism to supply said gridline material to said first inlet port and a sacrificial material to said second inlet port of said extrusion printhead assembly such that said gridline material and said sacrificial material are co-extruded from said plurality of dispensing orifices of said extrusion printhead assembly such that the gridline material forms a high-aspect ratio gridline structure on the substrate that is supported between two portions of said sacrificial material. 10. The method according to claim 9, wherein said method comprises, during said first time period, causing said material feed mechanism to supply said gridline material to said first inlet port at a first pressure and to supply said sacrificial material to said second inlet port at a second pressure, wherein the first and second pressures are selected such that a larger volume of said gridline material is forced through each of the plurality of dispensing orifices during said first time period than during said second time period, thereby forming said first endpoint structures. 11. The method according to claim 10, wherein said method comprises, during said second time period, causing said material feed mechanism to supply said gridline material to said first inlet port at a third pressure and to supply said sacrificial material to said second inlet port at a fourth pressure, wherein the third and fourth pressures are selected such that a larger volume of said sacrificial material is forced through each of the plurality of dispensing orifices during said second time period than during said first time period, thereby forming said central gridline portions supported between said two portions of said sacrificial material. 12. The method according to claim 11, wherein said method comprises, during said third time period, causing said material feed mechanism to supply said gridline material to said first inlet port at a fifth pressure and to supply said sacrificial material to said second inlet port at a sixth pressure, wherein the fifth and sixth pressures are selected such that a larger volume of said gridline material is forced through each of the plurality of dispensing orifices during said third time period than during said second time period, thereby forming said second endpoint structures. 13. The method according to claim 12, wherein the first and fifth pressures are equal, and wherein the second and sixth pressures are equal. 14. The method according to claim 12, further comprising, after forming said second endpoint structures, removing said two portions of said sacrificial material from said high-aspect ratio gridline structure. 15. The method according to claim 1, wherein forming said one or more busbars comprises depositing a paste on said target substrate; and wherein forming said central gridline portions comprises forming said vertex portions on said one or more busbars while said paste is still wet.
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이 특허에 인용된 특허 (38)
van der Heijden Edgar I. M.,NLX, Aerosol intended for dispensing a multi-component material.
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Joseph Anthony Gabriele, Nozzle apparatus, a device for inserting materials into a container using such nozzle apparatus, and a container containing materials inserted therein with the use of such device.
Deevi Seetharama C. (Midlothian VA) Fleischhauer Grier S. (Midlothian VA) Keen ; Jr. Billy J. (Chesterfield VA), Reinforced carbon heater with discrete heating zones.
Russell Philip P. (El Cerrito CA) Niu Tyan-Faung (Endwell NY) Holland Frederic A. (Rochester NY), Simultaneous formation and deposition of multiple ribbon-like streams.
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