Solar battery and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-9799788-B2
Application number	US-201013266606-A
Country	US
Kind code	B2
Filing date	Jun 30, 2010
Priority date	Jun 30, 2009
Publication date	Oct 24, 2017
Grant date	Oct 24, 2017

Abstract

A solar battery includes a polymer resin layer on a solar cell and an upper substrate on the polymer resin layer. A pattern is formed in the polymer resin layer.

First claim

The invention claimed is:

1. A solar battery comprising:
a solar cell comprising a rear electrode pattern, a light absorption layer, a buffer layer, and a front electrode layer;
a polymer resin layer disposed on the front electrode layer; and
an upper substrate disposed on the polymer resin layer;
wherein an upper surface of the polymer resin layer comprises a concave pattern and a flat surface portion formed therein and a lower surface of the polymer resin layer has a flat surface, and the flat surface of the lower surface of the polymer resin layer is in contact with an upper surface of the front electrode layer;
wherein the flat surface portion is disposed over an active area of the solar cell and beside the concave pattern, and the concave pattern is disposed over a non-active area of the solar cell;
wherein the polymer resin layer is disposed on the solar cell with the concave pattern facing away from the solar cell such that an upper part of the concave pattern is wider than a lower part of the concave pattern;
wherein the upper part of the concave pattern is farther away from the solar cell, in a longitudinal direction perpendicular to the upper surface of the solar cell, than is the lower part of the concave pattern;
wherein the upper substrate comprises a protrusion that is inserted into the concave pattern;
wherein the solar cell comprises a contact pattern formed through the light absorption layer and the buffer layer and a separation pattern separating regions of the buffer layer and separating regions of the front electrode layer;
wherein the separation pattern is formed as a transparent opening and an inner part of the separation pattern is empty;
wherein the rear electrode pattern is partially exposed through the contact pattern; and
wherein a material of the front electrode layer inserted in the contact pattern forms an interconnection for connecting the rear electrode pattern and the front electrode layer.

2. The solar battery according to claim 1 , wherein a sidewall of the concave pattern is sloped.

3. The solar battery according to claim 1 , wherein the concave pattern has a notch-shaped or curved section, and
wherein the protrusion has a shape corresponding to the notch-shaped or curved section of the concave pattern.

4. The solar battery according to claim 1 , wherein an entire width of the concave pattern is disposed directly over the non-active area of the solar cell in the longitudinal direction.

5. The solar battery according to claim 1 , wherein the polymer resin layer comprises ethyl vinyl acetate (EVA).

6. A method for manufacturing a solar battery, comprising:
forming a solar cell comprising a rear electrode pattern, a light absorption layer, a buffer layer, and a front electrode layer;
forming a polymer resin layer on the front electrode layer;
forming a pattern and a flat surface portion on an upper surface of the polymer resin layer, wherein the pattern comprises a concave pattern and a lower surface of the polymer resin layer has a flat surface, and the flat surface of the lower surface of the polymer resin layer is in contact with an upper surface of the front electrode layer; and
placing an upper substrate on the polymer resin layer where the pattern is formed;
wherein the flat surface portion is disposed over an active area of the solar cell and beside the pattern, and the concave pattern is disposed over a non-active area of the solar cell;
wherein the concave pattern faces away from the solar cell such that an upper part of the concave pattern is wider than a lower part of the concave pattern;
wherein the upper part of the concave pattern is farther away from the solar cell, in a longitudinal direction perpendicular to the upper surface of the solar cell, than is the lower part of the concave pattern;
wherein the upper substrate comprises a protrusion that is inserted into the concave pattern;
wherein the solar cell comprises a contact pattern formed through the light absorption layer and the buffer layer and a separation pattern separating regions of the buffer layer and separating regions of the front electrode layer;
wherein the separation pattern is formed as a transparent opening and an inner part of the separation pattern is empty;
wherein the rear electrode pattern is partially exposed through the contact pattern; and
wherein a material of the front electrode layer inserted in the contact pattern forms an interconnection for connecting the rear electrode pattern and the front electrode layer.

7. The method according to claim 6 , wherein an entire width of the concave part is disposed directly over the non-active area of the solar cell in the longitudinal direction.

8. The method according to claim 6 , wherein the polymer resin layer is disposed between the solar cell and the upper substrate, and wherein the placing of the upper substrate is performed by disposing the protrusion of the upper substrate in the concave part.

Assignees

• Lee Dong Keun
• Lg Innotek Co Ltd

Inventors

• Lee Dong Keun

Classifications

• Y02E10/52

  PV systems with concentrators · CPC title

• H01L31/0547

  Electricity · mapped topic

• H01L31/056 Primary

  Electricity · mapped topic

• H01L31/0543

  Electricity · mapped topic

• H01L31/0488

  Electricity · mapped topic