Solar cell with high aspect ratio gridlines supported between co-extruded support structures

摘要

A solar cell structure formed by extruding/dispensing materials on a substrate such that centrally disposed conductive high aspect ratio line structures (gridlines) are formed on the substrate surface with localized support structures coincidentally disposed on opposing side surfaces of the gridlines such that the gridlines are surrounded or otherwise supported by the localized support structures. In one embodiment the localized support structures are transparent, remain on the substrate after the co-extrusion process, and are covered by a layer of material. In another embodiment, the localized support structures are sacrificial support structures that are removed as part of the solar cell structure manufacturing process. In both cases the co-extrusion process is performed such that both the central gridline and the localized support structures are in direct contact with the surface of the substrate.

主权项

1. An intermediate structure comprising:
a substrate; and a plurality of parallel gridlines on the substrate, wherein each of the plurality of parallel gridlines includes: a central line structure comprising a first non-Newtonian fluid and having an aspect ratio, wherein the first non-Newtonian fluid comprises a silver paste, and a sacrificial support structure comprising a second non-Newtonian fluid, wherein the second non-Newtonian fluid is in contact with the first non-Newtonian fluid such that side portions of the sacrificial support structure contact opposing side edges of the central line structure, wherein the second non-Newtonian fluid is configured to maintain a cross sectional shape of the central line structure, and wherein each sacrificial support structure is localized to only a single gridline; wherein the central line structure of all of the plurality of parallel gridlines cover less than 4% of a surface area of said substrate.