Sunpower Corporation

Xi Zhu

David D Smith

Seung Bum Rim

Michael Cudzinovic

Michael C Johnson

Joseph Frederick Behnke

Xiuwen Tu

Junbo Wu

Richard Sewell Hamilton

Methods and structures for forming a contact region on a solar cell are presented. The solar cell can have a front side which faces the sun during normal operation, and a back side opposite the front side and a silicon substrate. The silicon substrate can include at least one doped region a dielectric layer formed over the doped region. The solar cell can also include a first metal contact, such as an electrolessly plated metal contact, within a contact region through a first dielectric layer and on the doped region. The solar cell can include a printed metal, such as aluminum, formed or deposited on the first metal contact. The solar cell can include a first metal layer having a first metal contact and the first printed metal. The solar cell can include a second metal layer, such as an electrolytically electroplated metal layer, formed on the first metal layer.

Conductivity enhancement of solar cells

Conductive contacts for solar cells and methods of forming conductive contacts for solar cells are described. For example, a solar cell includes a substrate. A conductive contact is disposed on the substrate. The conductive contact includes a layer composed of a first metal species having a plurality of pores. The conductive contact also includes a second metal species disposed in the plurality of pores. Portions of both the first and second metal species are in contact with the substrate.

Conductive contact for solar cell

A solar cell, having a front side which faces the sun during normal operation, and a back side opposite the front side can include a silicon substrate having doped regions and a polysilicon layer disposed over the doped regions. The solar cell can include a conductive filling formed between a first metal layer and doped regions and through or at least partially through the polysilicon layer, where the conductive filling electrically couples the first metal layer and the doped region. In an embodiment, a second metal layer is formed on the first metal layer, where the first metal layer and the conductive filling electrically couple the doped regions and the second metal layer. In some embodiments, the solar cell can be a front contact solar cell or a back contact solar cell.

Reduced contact resistance and improved lifetime of solar cells

Enhanced adhesion of seed layers for solar cell conductive contacts and methods of forming solar cell conductive contacts are described. For example, a method of fabricating a solar cell includes forming an adhesion layer above an emitter region of a substrate. A metal seed paste layer is formed on the adhesion layer. The metal seed paste layer and the adhesion layer are annealed to form a conductive layer in contact with the emitter region of the substrate. A conductive contact for the solar cell is formed from the conductive layer.

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Milpitas, CA, United States of America

Xi Zhu