High throughput laser processing

Patent metadata

Field	Value
Publication number	US-9527164-B2
Application number	US-201414491662-A
Country	US
Kind code	B2
Filing date	Sep 19, 2014
Priority date	Jul 1, 2010
Publication date	Dec 27, 2016
Grant date	Dec 27, 2016

Abstract

A solar cell is formed using a solar cell ablation system. The ablation system includes a single laser source and several laser scanners. The laser scanners include a master laser scanner, with the rest of the laser scanners being slaved to the master laser scanner. A laser beam from the laser source is split into several laser beams, with the laser beams being scanned onto corresponding wafers using the laser scanners in accordance with one or more patterns. The laser beams may be scanned on the wafers using the same or different power levels of the laser source.

First claim

What is claimed is:

1. A method of fabricating a solar cell, the method comprising:
splitting a laser beam from a laser source into a first laser beam along a first laser beam path and a second laser beam along a second laser beam path;
applying the first laser beam at a first power level to a first wafer at a first station according to a first pattern;
applying the second laser beam at the first power level to a second wafer at a second station according to the first pattern;
moving the first wafer from the first station to the second station; and
applying the second laser beam to the first wafer at a second power level that is different from the first power level at the second station according to a second pattern.

2. The method of claim 1 , wherein said applying the first laser beam at the first power level to the first wafer includes ablating material from the first wafer in accordance with the first pattern.

3. The method of claim 1 , wherein said applying the first laser beam at the first power level to the first wafer includes heating material from the first wafer in accordance with the first pattern.

4. The method of claim 1 , wherein said applying the first laser beam at the first power level to the first wafer forms contact holes that expose a diffusion region of a solar cell being fabricated on the first wafer, and further comprising forming a metal contact into the contact holes to electrically connect to the diffusion region.

5. The method of claim 1 , wherein said moving the first wafer from the first station to the second station includes rotating a surface supporting the first wafer from a first position to a second position.

6. The method of claim 1 , further comprising:
moving the first wafer from the second station and a third wafer to the first station; and
applying the first laser beam at the first power level to the third wafer at the first station according to the first pattern.

Assignees

• Sunpower Corp

Inventors

• Harley Gabriel
• Pass Thomas
• Cousins Peter John
• Viatella John

Classifications

• B23K2103/50

  Inorganic materials other than metals or composite materials · CPC title

• B23K26/067

  Dividing the beam into multiple beams, e.g. multi-focusing · CPC title

• B23K26/0823

  Devices involving rotation of the workpiece · CPC title

• B23K26/082

  Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head · CPC title

• Y02E10/547

  Monocrystalline silicon PV cells · CPC title