Wire-based metallization and stringing for solar cells
Wire-based metallization and stringing techniques for solar cells, and the resulting solar cells, modules, and equipment, are described. In an example, a substrate has a surface. A plurality of N-type and P-type semiconductor regions is disposed in or above the surface of the substrate. A conductive contact structure is disposed on the plurality of N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of conductive wires, each conductive wire of the plurality of conductive wires essentially continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions.
1. A solar cell comprising:
a substrate having a surface;
a plurality of N-type and P-type semiconductor regions disposed in or above the surface of the substrate;
a conductive contact structure disposed on the plurality of N-type and P-type semiconductor regions, the conductive contact structure comprising a plurality of conductive wires, each conductive wire of the plurality of conductive wires continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions over a length of greater than 10 mm without a weld, wherein a conductive wire of the plurality of conductive wires has a first portion and a second portion, wherein the first portion of the conductive wire has a substantially flat surface with microgrooves extending along a length of the conductive wire in the first direction, and wherein the second portion of the conductive wire is substantially round and has a substantially smooth surface.
2. The solar cell of claim 1 , wherein each conductive wire of the plurality of conductive wires is parallel along a direction to form a one-dimensional layout of the conductive contact structure.
3. The solar cell of claim 1 , wherein the substrate is substantially rectangular, and wherein the plurality of N-type and P-type semiconductor regions and the plurality of conductive wires are substantially parallel to an edge of each of the substrate.
4. The solar cell of claim 1 , wherein the plurality of N-type and P-type semiconductor regions is disposed in a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
5. The solar cell of claim 1 , wherein the plurality of N-type and P-type semiconductor regions is disposed above a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
6. The solar cell of claim 1 , wherein the first portion of the conductive wire is positioned over the corresponding one of the N-type and P-type semiconductor regions, and the second portion of the conductive wire extends off the surface of the substrate.
7. A solar cell comprising:
a substrate having a surface;
a plurality of N-type and P-type semiconductor regions disposed in or above the surface of the substrate;
a conductive contact structure disposed on the plurality of N-type and P-type semiconductor regions, the conductive contact structure comprising a plurality of non-coated conductive wires, each non-coated conductive wire of the plurality of non-coated conductive wires continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions over a length of greater than 10 mm without a weld, wherein a conductive wire of the plurality of non-coated conductive wires has a first portion and a second portion, wherein the first portion of the conductive wire has a substantially flat surface with microgrooves extending along a length of the conductive wire in the first direction, and wherein the second portion of the conductive wire is substantially round and has a substantially smooth surface.
8. The solar cell of claim 7 , wherein each non-coated conductive wire of the plurality of non-coated conductive wires is parallel along a direction to form a one-dimensional layout of the conductive contact structure.
9. The solar cell of claim 7 , wherein the substrate is substantially rectangular, and wherein the plurality of N-type and P-type semiconductor regions and the plurality of non-coated conductive wires are substantially parallel to an edge of each of the substrate.
10. The solar cell of claim 7 , wherein the plurality of N-type and P-type semiconductor regions is disposed in a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
11. The solar cell of claim 7 , wherein the plurality of N-type and P-type semiconductor regions is disposed above a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
12. The solar cell of claim 7 , wherein the first portion of the conductive wire is positioned over the corresponding one of the N-type and P-type semiconductor regions, and the second portion of the conductive wire extends off the surface of the substrate.
13. A solar cell comprising:
a substrate having a surface;
a plurality of N-type and P-type semiconductor regions disposed in or above the surface of the substrate;
a conductive contact structure disposed on the plurality of N-type and P-type semiconductor regions, the conductive contact structure comprising a plurality of conductive wires extending along a first direction, each conductive wire of the plurality of conductive wires essentially continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions along the first direction, wherein a conductive wire of the plurality of conductive wires has a first portion and a second portion, wherein the first portion of the conductive wire has a substantially flat surface with microgrooves extending along a length of the conductive wire in the first direction, and wherein the second portion of the conductive wire is substantially round and has a substantially smooth surface.
14. The solar cell of claim 13 , wherein each conductive wire of the plurality of conductive wires is parallel along a direction to form a one-dimensional layout of the conductive contact structure.
15. The solar cell of claim 13 , wherein the substrate is substantially rectangular, and wherein the plurality of N-type and P-type semiconductor regions and the plurality of conductive wires are substantially parallel to an edge of each of the substrate.
16. The solar cell of claim 13 , wherein the plurality of N-type and P-type semiconductor regions is disposed in a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
17. The solar cell of claim 13 , wherein the plurality of N-type and P-type semiconductor regions is disposed above a back surface of the substrate, the back surface opposite an opposing light-receiving surface of the substrate.
18. The solar cell of claim 13 , wherein the first portion of the conductive wire is positioned over the corresponding one of the N-type and P-type semiconductor regions, and the second portion of the conductive wire extends off the surface of the substrate.