IP Library Granted Patent US 11,398,576
Granted Patent B2
US 11,398,576 · App. 16/832,819 · Granted Jul 26, 2022

Solar cell having a plurality of sub-cells coupled by a metallization structure

Inventors: Gabriel Harley (Mountain View, CA); Michael Morse (San Jose, CA); Peter John Cousins (Los Altos, CA)
Assignee: SunPower Corporation
H01L31/0516H01L31/028H01L31/048H01L31/0475H01L31/0504H01L31/0682H01L31/02363H01L31/1876Y02E10/547Y02P70/50
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Quick Facts
Patent No.
US 11,398,576
App. No.
16/832,819
Granted
Jul 26, 2022
Kind
B2
Abstract

Solar cells having a plurality of sub-cells coupled by metallization structures, and singulation approaches to forming solar cells having a plurality of sub-cells coupled by metallization structures, are described. In an example, a solar cell, includes a plurality of sub-cells, each of the sub-cells having a singulated and physically separated semiconductor substrate portion. Adjacent ones of the singulated and physically separated semiconductor substrate portions have a groove there between. The solar cell also includes a monolithic metallization structure. A portion of the monolithic metallization structure couples ones of the plurality of sub-cells. The groove between adjacent ones of the singulated and physically separated semiconductor substrate portions exposes a portion of the monolithic metallization structure.

Claims (30)

1. A solar cell, comprising:

a plurality of physically separated sub-cells formed upon singulation of a silicon substrate of a photovoltaic solar cell, the plurality of physically separated sub-cells comprising a scribe portion between pairs of ones of the singulated and physically separated sub-cells, wherein the scribe portion is disposed through the entire depth of the silicon substrate; and

a metallization structure located over and covering the scribe portion from end-to-end between the pairs of the ones of the plurality of singulated and physically separated sub-cells, the metallization structure bonded to a back surface, opposite a light-receiving surface, of each of the plurality of singulated and physically separated sub-cells, wherein the metallization structure electrically bridges at least two of the plurality of singulated and physically separated sub-cells, wherein the metallization structure electrically interconnects a first doped region of a first of the at least two of the plurality of singulated and physically separated sub-cells and a second doped region of a second of the at least two of the plurality of singulated and physically separated sub-cells.

2. The solar cell of claim 1 , wherein the metallization structure comprises a metal foil.

3. The solar cell of claim 1 , wherein the metallization structure comprises an aluminum foil.

4. The solar cell of claim 1 , wherein the metallization structure comprises a plated metal.

5. The solar cell of claim 1 , wherein the metallization structure comprises a ribbon.

6. The solar cell of claim 1 , wherein the plurality of singulated and physically separated sub-cells is a plurality of in-parallel diodes, in-series diodes, or a combination thereof.

7. The solar cell of claim 1 , wherein the silicon substrate comprises a bulk monocrystalline silicon substrate.

8. The solar cell of claim 1 , wherein the metallization structure is a continuous metallization structure.

9. The solar cell of claim 1 , wherein each of the scribe portions comprises a curved surface.

10. A solar cell, comprising:

a plurality of physically separated sub-cells formed upon singulation of a silicon substrate of a photovoltaic solar cell, the plurality of physically separated sub-cells comprising a scribe portion between pairs of ones of the singulated and physically separated sub-cells, wherein the scribe portion is disposed through the entire depth of the silicon substrate; and

a metallization structure located over and covering the scribe portion from end-to-end between the pairs of the ones of the plurality of singulated and physically separated sub-cells, the metallization structure bonded to a back surface, opposite a light-receiving surface, of each of the plurality of singulated and physically separated sub-cells, the scribe portion disposed partially into the metallization structure, wherein the metallization structure electrically bridges at least two of the plurality of singulated and physically separated sub-cells.

11. The solar cell of claim 10 , wherein the metallization structure comprises a metal foil.

12. The solar cell of claim 10 , wherein the metallization structure comprises an aluminum foil.

13. The solar cell of claim 10 , wherein the metallization structure comprises a material selected from the group consisting of plated metal and a ribbon.

14. The solar cell of claim 10 , wherein the plurality of singulated and physically separated sub-cells is a plurality of in-parallel diodes, in-series diodes, or a combination thereof.

15. The solar cell of claim 10 , wherein the silicon substrate comprises a bulk monocrystalline silicon substrate.

16. A solar cell, comprising:

a plurality of physically separated sub-cells formed upon singulation of a silicon substrate of a photovoltaic solar cell, the plurality of physically separated sub-cells comprising a scribe portion between pairs of ones of the singulated and physically separated sub-cells, wherein the scribe portion is disposed through the entire depth of the silicon substrate;

a metallization structure located over and covering the scribe portion from end-to-end between the pairs of the ones of the plurality of singulated and physically separated sub-cells, the metallization structure bonded to a back surface, opposite a light-receiving surface, of each of the plurality of singulated and physically separated sub-cells, wherein the metallization structure electrically bridges at least two of the plurality of singulated and physically separated sub-cells; and

a damage buffer portion disposed on the metallization structure and between pairs of ones of the singulated and physically separated sub-cells, wherein the scribe portion disposed on the damage buffer portion.

17. The solar cell of claim 16 , wherein the scribe portion is disposed partially into the damage buffer portion.

18. The solar cell of claim 16 , wherein the damage buffer portion comprises a polymer material.

19. The solar cell of claim 16 , wherein the damage buffer portion comprises a metal distinct from the metallization structure.

20. The solar cell of claim 16 , wherein the damage buffer portion comprises a material selected from the group consisting of a printed material and a tape.

21. The solar cell of claim 1 , wherein the metallization structure has a strain relief feature therein, the strain relief feature over a portion of the scribe portion between the pairs of the ones of the plurality of singulated and physically separated sub-cells.

22. The solar cell of claim 21 , wherein the strain relief feature comprises and opening.

23. The solar cell of claim 1 , wherein the metallization structure covers an entirety of the scribe portion between the pairs of the ones of the plurality of singulated and physically separated sub-cells.

Assignments (5)
SECURITY INTEREST Recorded Jun 27, 2024
From: MAXEON SOLAR PTE. LTD.
To: DB TRUSTEES (HONG KONG) LIMITED
Reel/Frame 067924/0062 →
SECOND LIEN SECURITY INTEREST AGREEMENT Recorded Jun 26, 2024
From: MAXEON SOLAR PTE. LTD
To: DB TRUSTEES (HONG KONG) LIMITED
Reel/Frame 071343/0553 →
SECURITY INTEREST Recorded Jun 5, 2024
From: MAXEON SOLAR PTE. LTD.
To: DB TRUSTEES (HONG KONG) LIMITED
Reel/Frame 067637/0598 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 24, 2023
From: SUNPOWER CORPORATION
To: MAXEON SOLAR PTE. LTD.
Reel/Frame 062699/0875 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 27, 2020
From: HARLEY, GABRIEL; MORSE, MICHAEL; COUSINS, PETER JOHN
To: SUNPOWER CORPORATION
Reel/Frame 052767/0061 →