WO2023272779A1 - 一种太阳能电池片电极制作方法及太阳能电池 - Google Patents

一种太阳能电池片电极制作方法及太阳能电池 Download PDF

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Publication number
WO2023272779A1
WO2023272779A1 PCT/CN2021/105831 CN2021105831W WO2023272779A1 WO 2023272779 A1 WO2023272779 A1 WO 2023272779A1 CN 2021105831 W CN2021105831 W CN 2021105831W WO 2023272779 A1 WO2023272779 A1 WO 2023272779A1
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screen
solar cell
metal mesh
slurry
adhesive
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PCT/CN2021/105831
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English (en)
French (fr)
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陈飞
詹兴华
周臣
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深圳纳弘熠岦光学科技有限公司
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Publication of WO2023272779A1 publication Critical patent/WO2023272779A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/0224—Electrodes
    • H01L31/022408—Electrodes for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/022425—Electrodes for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/0224—Electrodes
    • H01L31/022408—Electrodes for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/022425—Electrodes for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • H01L31/022433—Particular geometry of the grid contacts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present application relates to the technical field of solar cells, in particular to a solar cell electrode manufacturing method and a solar cell.
  • Grid wire electrodes in existing solar cells are prepared by screen printing.
  • the scraper is in contact with the transfer screen, and the screen is deformed. Since the screen touches the surface of the cell, when the scraper leaves, the screen will lift up the silver paste due to the adhesion between the surface of the screen and the silver paste. , so that the silver paste forms a grid line with a parabolic envelope, resulting in uneven line width of the grid line, which affects the use of solar cells.
  • the main purpose of this application is to propose a solar cell electrode manufacturing method, which aims to solve the technical problems of large grid line width, uneven grid line width and height, and poor grid line shape during the grid line electrode manufacturing process.
  • the present application proposes a method for manufacturing solar cell electrodes, comprising the following steps:
  • the screen plate includes a screen frame, a silk screen, a metal mesh, and a continuous material layer
  • the screen plate production step includes:
  • the metal layer on the surface of the microstructure mold is thickened by electroforming to form a metal mesh.
  • the screen making step also includes:
  • the metal mesh is bonded to the continuous material layer through an adhesive C;
  • the step of bonding the metal mesh to the continuous material layer through an adhesive C also includes:
  • the adhesive C is solidified to form a glue layer
  • place the metal mesh directly on the glue layer bond the metal mesh and the continuous material layer under high temperature and high pressure conditions, and then use a laser to Through the through holes on the metal mesh, the glue layer is carved to form a corresponding grid line structure on the glue layer.
  • the conditions of high temperature and high pressure are temperature between 60°C and 250°C, bonding pressure between 8kg and 200kg, and holding time of heat preservation and pressure for 10 to 30 minutes.
  • the adhesive B is made of epoxy resin glue, hot melt adhesive, or latex, and the adhesive B can be in the form of glue or film;
  • the adhesive C is made of epoxy resin glue, hot melt adhesive, UV glue, pressure-sensitive adhesive, or latex, and the adhesive C can be in the form of glue or film;
  • the adhesive A is made of one of hot melt adhesive and latex, and the adhesive A can be in the form of glue or film.
  • the continuous material layer is a composite layer of net-like weaving structure
  • the mesh number of the net-like weaving structure composite layer ranges from 150 mesh to 650 mesh
  • the mesh-like weaving structure composite layer is made of steel, nickel, nickel-cobalt One or more of alloy, copper-nickel alloy, glass fiber mesh.
  • the battery sheets are placed under the screen at intervals; the slurry is placed on the screen; the slurry is extruded from the mesh of the screen and deposited on the surface of the battery sheet while maintaining The screen plate is in non-contact/micro-contact with the battery sheet; the step of making the slurry solidify on the surface of the battery sheet to form an electrode also includes:
  • the cells are put into a solar cell sintering furnace for sintering treatment, so that the slurry is solidified on the surface of the cells to form metal grid wire electrodes.
  • step of placing the cells at intervals under the screen includes:
  • the distance between the metal mesh and the battery sheet is the distance between the lower surface of the metal mesh and the battery sheet, and the distance is 0.03mm-2mm;
  • Adjusting the paste material includes adjusting the composition of the paste and the viscosity of the paste, and the composition of the paste includes silver paste, copper paste, and aluminum paste.
  • the electrodes include main grid lines and auxiliary grid lines, the width of the main grid lines is 0.03mm-1mm, the height of the main grid lines is 0.013mm-0.1mm; the width of the auxiliary grid lines is 0.005 mm-0.03mm, the height of the thin grid lines is 0.005mm-0.04mm; the shapes of the main grid lines and auxiliary grid lines include rectangle, triangle, trapezoid, and parabola.
  • the present application also provides a solar cell, including an electrode, and the electrode is manufactured by using the above solar cell electrode manufacturing method.
  • the technical solution provides a method for manufacturing solar cell electrodes.
  • the manufacturing method adopts a transfer printing through-hole screen of a metal mesh.
  • the transfer printing through-hole screen has a small amount of deformation and is non-contact or Micro-contact, so that the grid line electrode can maintain a good line shape, and the line shape of the grid line is more standardized.
  • the grid line electrode manufactured by the manufacturing method is straight and uniform, which is beneficial to reduce the loss of slurry and reduce the production cost.
  • FIG. 1 is a schematic flowchart of steps of an embodiment of a method for manufacturing a solar cell electrode of the present application.
  • Fig. 2 is a top view of the transfer through-hole screen of the present application.
  • Fig. 3 is a side sectional view of the transfer through-hole screen of the present application.
  • FIG. 4 is a schematic diagram of the cross-sectional shape of the microstructure through hole of the metal mesh of the present application.
  • the manufacturing method includes the following steps:
  • the slurry is solidified on the surface of the battery sheet to form an electrode.
  • the paste is a conductive metal paste
  • the screen is a through-hole screen for transfer.
  • the screen is directly applied to the cell screen printing equipment, and the metal paste is transferred through the screen.
  • S30 Squeeze the slurry into the microstructure through-holes of the metal mesh with a certain pressure, so that the slurry is shaped according to the shape of the microstructure through-holes;
  • the metal mesh has a certain thickness
  • the microstructure through hole has a three-dimensional structure according to the design
  • the metal paste when the metal paste enters the microstructure through hole of the metal mesh, due to the fluidity of the metal paste, the metal paste is subjected to Extruded by external force, the metal paste shapes itself according to the shape of the microstructure through hole; when the scraper passes by, it brings more metal paste and pushes down, displacing the original metal paste in the microstructure through hole Extrude onto the cell surface to complete the transfer printing process.
  • the cross-sectional shape of the above-mentioned microstructure through hole includes a binary geometric figure with a certain relationship between the width of the upper and lower regions, and a multivariate geometric figure with a variable width of the upper, middle and lower regions.
  • the binary geometry includes Rectangular, trapezoidal, triangular, and parabolic shapes;
  • the multivariate geometric figures include trapezoidal, triangular, and parabolic shapes with top width, middle narrowness, and bottom width, or top narrowness, middle width, and bottom narrowness. And change.
  • the step of placing the cells under the screen at intervals is as follows:
  • the distance between the metal mesh and the battery sheet is the distance between the lower surface of the metal mesh and the battery sheet, and the distance is 0.03mm-2mm;
  • the downward pressure of the scraper determines the amount of compression deformation of the transfer screen plate and the size of the slurry. output, the adjustment needs to be determined according to the specific cell electrode morphology parameters;
  • adjusting the slurry material includes adjusting the composition of the slurry and the viscosity of the slurry, the composition of the slurry includes silver paste, copper paste, aluminum paste, etc.
  • the printing parameters are adjusted as follows: the distance between the metal mesh and the battery sheet is -500 to -1600, the distance between the ink flooding knife and the scraper surface of the screen is less than 4mm, and the depth of the scraper is 1000mm. To 1600, the squeegee pressure is 40N-70N, when printing, 10 ⁇ 20% more silver paste is added to the screen than usual.
  • the electrodes include main grid lines and auxiliary grid lines, the width of the main grid lines is 0.03mm-1mm, the height of the main grid lines is 0.013mm-0.1mm; the width of the auxiliary grid lines is 0.005 mm-0.03mm, the height of the fine grid lines is 0.005mm-0.04mm.
  • the shapes of the main grid lines and the auxiliary grid lines include rectangle, triangle, trapezoid and parabola.
  • the grid electrode can maintain a good line shape, and the grid line shape is more standardized.
  • the application also proposes a transfer printing through-hole screen and a manufacturing method thereof.
  • the screen plate includes a screen frame 11 , a wire mesh 12 , a metal mesh 14 and a continuous material layer 13 .
  • Described screen version production step comprises:
  • the metal mesh 14 is laid on the continuous material layer 13;
  • S103 Align the metal mesh 14 with the glue layer, and bond the metal mesh 14 and the continuous material layer 13 under high temperature and high pressure conditions.
  • the pattern drawing means adopts laser engraving or developing and exposing, and the pattern of the cell electrode can be drawn on the glue to form a glue layer with a through-hole structure.
  • the above-mentioned solar cell electrode manufacturing method also includes the following steps:
  • S400 Coat photosensitive resin or photosensitive emulsion on the other side of the continuous material layer, and bake and cure;
  • the specific figure includes a funnel shape, a rectangle, a trapezoid, and a semicircle, and the width of the specific figure is greater than or equal to the width of the gate line.
  • the adhesive B is made of epoxy resin glue, hot melt adhesive, or latex, and the adhesive B can be in the form of glue or film;
  • the adhesive C is made of epoxy resin glue, hot melt adhesive, UV glue, pressure-sensitive adhesive, or latex, and the adhesive C can be in the form of glue or film;
  • the adhesive A is made of one of hot melt adhesive and latex, and the form of the adhesive A can be glue or film.
  • the high temperature and high pressure conditions are temperature between 60°C and 250°C, bonding pressure between 8kg and 200kg, and holding time for heat preservation and pressure for 10 to 30 minutes.
  • the solar cell sheet electrode manufacturing method wherein the manufactured screen includes a 22.5 ° oblique screen and a knotless screen.
  • the continuous material layer 15 is a composite layer with a net-like braided structure, which is formed by laminating filaments of various materials and weaving warp and weft threads intersecting each other.
  • the mesh number range of the mesh-like weaving structure composite layer is 150 mesh to 650 mesh, and the continuous material layer 15 is specifically a mesh composite layer, and the mesh composite layer includes multi-layered mesh, and this type of mesh can be: nylon Mesh, metal mesh or mesh made of other materials.
  • the mesh is made of one or more materials of steel, nickel, nickel-cobalt alloy, copper-nickel alloy, and glass fiber mesh.
  • the continuous material layer 15 can be produced by precision mechanical weaving, metal electroforming process, corrosion process, photolithography process and other methods.
  • the function of the continuous material layer 15 is as follows: 1. Support the metal mesh. During the forming process of the cell electrode, the continuous material layer 15 can disperse most of the downward pressure of the scraper of the screen printing equipment and prolong the life of the transfer screen. Lifespan; 2. To preserve the slurry, the continuous material layer 15 is a composite layer with a network structure, so the material layer can keep the metal slurry in itself. When the scraper of the silk screen printing equipment scrapes it, the continuous material layer itself is compressed. The slurry is extruded and sent into the mesh of the metal mesh; 3.
  • Control the discharge amount of the metal slurry, the amount of slurry that the continuous material layer 15 itself can contain and the deformation of the continuous material layer itself determine the single For the output of the slurry during transfer printing, the softer the continuous material layer 15 and the larger the volume of the porous structure, the greater the output of the slurry, and vice versa.
  • the application also proposes a metal mesh and a manufacturing method thereof.
  • the metal mesh has microstructure through-holes on the order of microns, and the microstructure through-holes can be line segments, round holes, square holes, and the like.
  • the surface roughness of the two sides of the metal mesh is different, and it is divided into a bright surface and a frosted surface.
  • the bright surface is the surface in contact with the battery sheet. Because of its smooth surface and low roughness, it has a release effect on the metal paste; the frosted surface
  • the non-adhesive surface due to its rough surface and large specific surface area, can be firmly bonded to the continuous material layer.
  • the role of the metal mesh is: 1.
  • the paste As a mask for metal paste printing, make the paste form battery electrode grid lines in the designated area of the battery sheet; 2. As the paste before depositing on the battery sheet The forming mold, the slurry is squeezed by pressure into the microstructure through holes of the metal mesh, the slurry is shaped due to its own fluidity and external pressure, so the final line shape of the electrodes on the battery sheet depends on the metal mesh The shape design of the microstructure through hole; 3. The metal mesh not only makes micro contact with the battery sheet in the subsequent forming process of the cell electrode, but also bears the pressure of the scraper of the screen printing equipment, so the material of the metal mesh determines the entire transfer screen. service life.
  • the manufacturing steps of the metal mesh include:
  • S800 Electroforming and thickening the metal layer on the surface of the microstructure mold to form a metal mesh.
  • step S500 the layout design of the grid lines of the metal mesh is carried out according to the solar cells, that is, the layout design is carried out according to the specific solar cell products, and the layout design needs to consider the design and arrangement of the following elements: Cloth: auxiliary grid lines (thickness, height, number of lines, period, etc.), anti-break grid lines, outer frame, positioning points, main grid, etc.
  • a microstructure mold is produced according to the layout design of the grid lines, that is, according to the layout design of the grid lines, a microstructure mold is produced by using micro-contact nanoimprinting technology, and the base of the mold is PET, PC, PI, PMMA Or one of the metal sheet materials.
  • step S700 the metallization treatment is carried out on the surface of the microstructure mold, that is, a layer of conductive metal layer is formed on the surface of the mold structure surface, and the conductive metal layer can be one of nickel, chromium, silver, and copper material.
  • the conductive metal layer can be made by physical vapor deposition (PVD), silver mirror reaction and other methods.
  • step S800 the metal layer on the surface of the microstructure mold is thickened by electroforming to form a metal mesh, that is, the metal layer of the surface metallized mold is thickened by electroforming to form a metal mesh.
  • Metals include: nickel, nickel-cobalt alloy, copper, copper-nickel alloy, etc.
  • the thickness of the metal mesh produced by the above-mentioned metal mesh production method is: 0.001mm-0.1mm; the thickness uniformity is: ⁇ 0.003mm; taper: 0 taper.
  • the side wall of the microstructure through hole is completely flat, which is mirror flatness, and there is no unevenness or pothole on the surface, and its warpage is 0 warpage.
  • the metal mesh has steel properties, and the side walls of the metal mesh microstructure through holes are flat, the metal mesh and the through hole are flat during the transfer printing process.
  • the battery sheet is non-contact or micro-contact, so that the formed grid electrode is straight and uniform, which is beneficial to reduce the loss of slurry, and then reduce the production cost; the formed solar cell can reduce the shading area and increase the thickness due to the thinner grid electrode. High current density, improve energy conversion efficiency.
  • the present application also provides a solar cell, which includes an electrode made by the above-mentioned solar cell electrode manufacturing method, and the specific structure of the electrode refers to the above-mentioned embodiment, since the solar cell adopts the above-mentioned solar cell electrode manufacturing method. All the technical solutions of the above-mentioned embodiments, therefore at least have all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, and will not be repeated here.
  • the directional indication is only used to explain the relationship between the components in a certain posture. If the specific posture changes, the directional indication will also change accordingly.

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Abstract

本申请公开一种太阳能电池片电极制作方法，该制作方法包括如下步骤：将电池片间隔置于网版下方；将浆料放置于网版上；挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；使浆料在电池片表面固化，形成电极；其中，所述网版包括网框、丝网、金属网、续料层，所述网版制作步骤包括：将所述金属网铺设于续料层上；将所述续料层与丝网贴合；以一定的张力绷紧丝网，使丝网固定在网框上。该制作方法采用金属网的转印通孔网版，在转印过程中，网版变形量小，并且与电池片保持非接触或微接触，从而使栅线电极可保持良好的线型，并且栅线电极平直均匀，有益于减少浆料的损耗，降低生产成本。

Description

一种太阳能电池片电极制作方法及太阳能电池
本申请要求于2021年7月2日提交中国专利局、申请号为202110753717.3发明名称为“一种太阳能电池片电极制作方法及太阳能电池”的中国专利申请的优先权，其全部内容通过引用结合在申请中。
技术领域
本申请涉及太阳能电池技术领域，特别涉及一种太阳能电池电极制作方法及太阳能电池。
 背景技术
随着太阳能电池行业的不断发展，内业竞争也在不断加剧，大型太阳能电池企业间并购整合与资本运作日趋频繁，国内优秀的太阳能电池生产企业愈来愈重视对行业市场的研究，特别是对产业发展环境和产品购买者的深入研究。正因为如此，一大批国内优秀的太阳能电池品牌迅速崛起，逐渐成为太阳能电池行业中的翘楚。
 技术问题
现有太阳能电池中的栅线电极通过丝网印刷法制备。在印刷过程中，刮刀与转印网版接触，网版发生形变，由于丝网接触电池片表面，当刮刀离开时，因丝网的表面与银浆的粘力，丝网将银浆带起，使银浆形成抛物线包络的栅线，导致栅线线宽不均匀，影响太阳能电池的使用。
 技术解决方案
本申请的主要目的是提出一种太阳能电池电极制作方法，旨在解决栅线电极制造过程中栅线宽度大、栅线宽度和高度不均匀、栅线的线型差等技术问题。
为实现上述目的，本申请提出一种太阳能电池片电极制作方法，包括如下步骤：
将电池片间隔置于网版下方；
将浆料放置于网版上；
挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；
使浆料在电池片表面固化，形成电极；
其中，所述网版包括网框、丝网、金属网、续料层，所述网版制作步骤包括：
将所述金属网铺设于续料层上；
将所述续料层与丝网贴合；及
以一定的张力绷紧丝网，使丝网固定在网框上。
进一步地，还包括金属网制作步骤：
根据太阳能电池片对金属网的栅线进行排布设计；
根据栅线的排布设计制作微结构模具；
对所述微结构模具表面进行金属化处理；及
对所述微结构模具表面的金属层进行电铸加厚，形成金属网。
进一步地，所述网版制作步骤还包括：
将所述金属网通过粘接剂C与所述续料层粘合；
将所述续料层通过粘接剂B与丝网粘合；及
以一定的张力绷紧丝网，使丝网通过粘接剂A与所述网框粘合；
其中，所述将所述金属网通过粘接剂C与所述续料层粘合的步骤还包括：
将粘接剂C均匀涂覆于续料层上；
待所述粘接剂C固化形成胶水层，在胶水层上用激光或者超声或者化学或者物理的方法刻画电池片栅线电极的图形；及
使金属网与胶水层进行对位，在高温高压的条件下将金属网与续料层粘合；
或者待粘接剂C固化形成胶水层后，将金属网直接放置于胶水层之上，在高温高压的条件下将金属网与续料层粘合，然后依据所需要的栅线图案，用激光透过金属网上的通孔，把胶水层刻穿，在胶水层上形成对应的栅线结构。
进一步地，所述高温高压的条件为温度60摄氏度到250摄氏度之间，粘合的压力为8kg到200kg之间，保温保压时间为10至30分钟。
进一步地，所述粘接剂B采用环氧树脂型胶水、热熔胶、乳胶其中的一种材质，所述粘接剂B形态可为胶水或者胶膜；
所述粘接剂C采用环氧树脂型胶水、热熔胶、UV胶、压敏胶、乳胶其中的一种材质，所述粘接剂C形态可为胶水或者胶膜；及
所述粘接剂A采用热熔胶、乳胶其中的一种材质，所述粘接剂A形态可为胶水或者胶膜。
进一步地，所述续料层为网状编制结构复合层，所述网状编制结构复合层的目数范围为150目至650目，所述网状编制结构复合层采用钢、镍、镍钴合金、铜镍合金、玻纤网其中的一种或多种材质。
进一步地，所述将电池片间隔置于网版下方；将浆料放置于网版上；挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；使浆料在电池片表面固化，形成电极的步骤还包括：
将电池片间隔置于网版下方；
将浆料均匀地填涂于续料层上；
通过一定的压力将浆料挤压入金属网具有的微结构通孔中，使浆料根据所述微结构通孔的形状成型；
驱动刮刀下压在续料层上，将更多的浆料挤入金属网中，使浆料从网版的微结构通孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；及
将电池片放进太阳能电池烧结炉中进行烧结处理，使浆料在电池片表面固化，形成金属栅线电极。
进一步地，所述将电池片间隔置于网版下方的步骤包括：
将电池片置于网版下方，调整金属网与电池片的间距，调整刮刀下压力以及浆料材质；
其中，金属网与电池片的间距为金属网下表面与电池片之间的距离，该距离为0.03mm-2mm；及
调整浆料材质包括调整浆料的组成成分以及浆料的粘稠度，所述浆料的组成成分包括银浆、铜浆、铝浆。
进一步地，所述电极包括主栅线和副栅线，所述主栅线的宽度为0.03mm-1mm，所述主栅线的高度为0.013mm-0.1mm；所述副栅线宽度为0.005mm-0.03mm，所述细栅线的高度为0.005mm-0.04mm；所述主栅线和副栅线的形状包括矩形、三角形、梯形、抛物线形。
本申请还提供一种太阳能电池，包括电极，所述电极采用上述太阳能电池电极制作方法制作而成。
 有益效果
本技术方案提供一种太阳能电池电极制作方法，该制作方法通过采用金属网的转印通孔网版，在转印过程中，转印通孔网版变形量小，并且与电池片非接触或微接触，从而使栅线电极可保持良好的线型，栅线线型更标准化。此外，采用该制作方法制作的栅线电极平直均匀，有益于减少浆料的损耗，降低生产成本。
 附图说明
图1为本申请太阳能电池电极制作方法一实施例的步骤流程示意图。
图2为本申请转印通孔网版俯视图。
图3为本申请转印通孔网版侧视剖面图。
图4为本申请金属网的微结构通孔横截面形状示意图。
附图标号说明：
11-网框，12-丝网，13-续料层，14-金属网。
本申请的实施方式
请参阅图1，本申请太阳能电池电极制作方法一实施例中，制作方法包括如下步骤：
将电池片间隔置于网版下方；
将浆料放置于网版上；
挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；及
使浆料在电池片表面固化，形成电极。
在本实施例中，所述浆料为可导电的金属浆料，所述网版为转印通孔网版，该网版直接应用在电池片丝印设备上，金属浆料通过该网版转印到电池片表面，形成电极线路。
进一步地，上述太阳能电池电极制作方法的步骤具体为：
S10：将电池片间隔置于网版下方；
S20：将浆料均匀地填涂于续料层上；
S30：通过一定的压力将浆料挤压入金属网具有的微结构通孔中，使浆料根据所述微结构通孔的形状成型；
S40：驱动刮刀下压在续料层上，将更多的浆料挤入金属网中，使浆料从网版的微结构通孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；及
S50：将电池片放进太阳能电池烧结炉中进行烧结处理，使浆料在电池片表面固化，形成金属栅线电极。
具体的，由于金属网具有一定厚度，而微结构通孔是根据设计而具有立体结构，在金属浆料进入金属网的微结构通孔时，由于金属浆料具有流动性，同时金属浆料受到外力的挤压，金属浆料依据微结构通孔的形状自我塑型；当刮刀经过时，带来更多的金属浆料并向下推挤，将原来在微结构通孔中的金属浆料挤出到电池片表面，从而完成转印过程。
进一步地，请参阅图4，上述微结构通孔的横截面形状包括上下区域宽度具有一定关系的二元几何图形、上中下区域宽度具有多变的多元几何图形，所述二元几何图形包括矩形、梯形、三角形、抛物线形；所述多元几何图形包括上宽中窄下宽或上窄中宽下窄的梯形、三角形、抛物线形，其中，宽窄部位的分布随着金属网形成图形的不同而有所变化。
值得注意的是，在此转印过程中，由于金属网钢性材质，当刮刀经过，整个网版变形量小，在调整好转印通孔网版间距后，可保持所述转印通孔网版与电池片非接触或微接触转印，因此挤出的成型的浆料由于只收到电池片表面张力的拉扯，成型的浆料不发生形变，而直接落到了电池片表面，可以维持在金属网内成型的形状，从而保证一个良好栅线线型的同时，降低碎片现象的发生概率。
进一步地，为了使转印过程中达到网版与电池片非接触/微接触的技术效果，上述S10：将电池片间隔置于网版下方的步骤具体为：
将电池片置于网版下方，调整金属网与电池片的间距，调整刮刀下压力以及浆料材质。
具体的，所述金属网与电池片的间距为金属网下表面与电池片之间的距离，该距离为0.03mm-2mm；刮刀下压力决定了转印网版的下压变形量以及浆料的输出量，该调整需要根据具体的电池片电极形貌参数来确定；调整浆料材质包括调整浆料的组成成分以及浆料的粘稠度，所述浆料的组成成分包括银浆、铜浆、铝浆等。此外，在另一实施例中，针对不同的印刷设备，印刷参数调整为：金属网与电池片的间距为-500至-1600，覆墨刀与网版刮刀面的距离小于4mm，刮刀深度1000至1600，刮刀压力为40N-70N，在印刷的时候，网版中加入比常规多10~20%的银浆。
进一步地，所述电极包括主栅线和副栅线，所述主栅线的宽度为0.03mm-1mm，所述主栅线的高度为0.013mm-0.1mm；所述副栅线宽度为0.005mm-0.03mm，所述细栅线的高度为0.005mm-0.04mm。所述主栅线和副栅线的形状包括矩形、三角形、梯形、抛物线形。
在上述太阳能电池电极制作方法中，由于转印过程中转印通孔网版与电池片非接触或微接触，从而使栅线电极可保持良好的线型，栅线线型更标准化。
请参阅图2-3，在本实施例中，本申请还提出一种转印通孔网版及其制作方法。所述网版包括网框11、丝网12、金属网14、续料层13。所述网版制作步骤包括：
将所述金属网14铺设于续料层13上；
将所述续料层15与丝网12贴合；及
以一定的张力绷紧丝网12，使丝网12固定在网框11上。
进一步地，所述网版制作步骤具体为：
S100：将所述金属网14通过粘接剂C与所述续料层13粘合；
S200：将所述续料层13通过粘接剂B与丝网12粘合；及
S300：以一定的张力绷紧丝网12，使丝网通过粘接剂A与所述网框粘合。
进一步地，上述S100：将所述金属网14通过粘接剂C与所述续料层13粘合的步骤中，其步骤具体为：
S101：将所述粘接剂C均匀涂覆于续料层13上；
S102：待所述粘接剂C固化形成胶水层，在胶水层上用激光或者超声或者化学或者物理的方法刻画电池片栅线电极的图形；及
S103：使金属网14与胶水层进行对位，在高温高压的条件下将金属网14与续料层13粘合。
进一步地，在其他实施例中，上述S100：将所述金属网14通过粘接剂C与所述续料层13粘合的步骤中，其步骤具体为：
S104：将所述粘接剂C均匀涂覆于续料层13上；及
S105：待所述粘接剂C固化形成胶水层，将金属网直接放置于胶水层之上，在高温高压的条件下将金属网与续料层粘合，然后依据所需要的栅线图案，用激光透过金属网上的通孔，把胶水层刻穿，在胶水层上形成对应的栅线结构。
具体的，在S102步骤中，该刻画图案手段采用激光雕刻或者显影曝光的方式，可将电池片电极的图形刻画于胶水之上，形成具有通孔结构的胶水层。
进一步地，上述太阳能电池片电极制作方法，还包括如下步骤：
S400：在续料层的另外一面涂上感光树脂或者感光乳剂，并且热烘烤固化；
S500：对位金属网的图形区域，用曝光显影的方式，在栅线区域之上形成特定的图形，以提高浆料印刷时的过墨性。
其中，所述特定的图形包括漏斗形、矩形、梯形、半圆形，所述特定的图形宽度均大于或等于栅线的宽度。
进一步地，在上述网版的制作步骤中，所述粘接剂B采用环氧树脂型胶水、热熔胶、乳胶其中的一种材质，所述粘接剂B形态可为胶水或者胶膜；所述粘接剂C采用环氧树脂型胶水、热熔胶、UV胶、压敏胶、乳胶其中的一种材质，所述粘接剂C形态可为胶水或者胶膜；所述粘接剂A采用热熔胶、乳胶其中的一种材质，所述粘接剂A形态可为胶水或者胶膜。
进一步地，在S103步骤中，所述高温高压的条件为温度60摄氏度到250摄氏度之间，粘合的压力为8kg到200kg之间，保温保压时间为10至30分钟。
进一步地，所述太阳能电池片电极制作方法，其中所述制作的网版包括22.5 o的斜网网版和无网结网版。
进一步地，在本实施例中，所述续料层15为网状编制结构复合层，由多种材料细丝通过叠层并且经纬线相互交叉编织而成。所述网状编制结构复合层的目数范围为150目至650目，续料层15具体为网纱复合层，网纱复合层包括多层叠层的网纱，该类网纱可以是：尼龙网纱，金属材质网纱或者其他材料构成的网纱。所述网纱采用钢、镍、镍钴合金、铜镍合金、玻纤网其中的一种或多种材质。所述续料层15可以通过精密机械编织、金属电铸工艺、腐蚀工艺、光刻工艺等方法制作。
在本实施例中，续料层15的作用为：1、支撑金属网，电池片电极成型的过程中，续料层15可以绝大部分分散丝印设备刮刀的下压力，延长转印网版的寿命；2、存续浆料，续料层15为网状结构复合层，因此该徐料层可以将金属浆料存续于自身当中，当丝印设备的刮刀刮过时，续料层本身被压缩，其中的浆料被挤压而送入金属网的网孔中；3、控制金属浆料的出料量，续料层15本身能够包含的浆料量以及续料层本身的形变量决定了单次转印时浆料的输出量，续料层15越柔软、多孔结构体积越大，浆料的输出量越大，反之越小。
在本实施例中，本申请还提出一种金属网及其制作方法。所述金属网上带有微米量级的微结构通孔，微结构通孔可以为线段、圆孔、方孔等。所述金属网两面表面的粗糙度不同，分为亮面与磨砂面，其亮面为与电池片接触的面，由于其表面光滑，粗糙度低，对于金属浆料有离型作用；磨砂面为粘接的面，由于其表面粗糙，比表面积大，可以很牢固的与续料层粘接在一起。在本实施例中，金属网的作用是：1、作为金属浆料印刷的掩膜版，在电池片的指定区域使浆料形成电池电极栅线；2、作为浆料在沉积到电池片之前的成型模具，浆料受到压力的挤压进入到金属网的微结构通孔中，浆料因自身的流动性以及外部的压力得到塑型，因此电池片上的电极最终的线型取决于金属网微结构通孔的形状设计；3、金属网在后续电池片电极成型的过程中不但与电池片微接触，同时也承受丝印设备刮刀的压力，因此金属网的材质的决定了整个转印网版的使用寿命。
所述金属网的制作步骤包括：
S500：根据太阳能电池片对金属网的栅线进行排布设计；
S600：根据栅线的排布设计制作微结构模具；
S700：对所述微结构模具表面进行金属化处理；及
S800：对所述微结构模具表面的金属层进行电铸加厚，形成金属网。
具体的，在步骤S500中，根据太阳能电池片对金属网的栅线进行排布设计，即根据具体的太阳能电池片产品而进行排布设计的，该排布设计需要考虑以下元素的设计和排布：副栅线（粗细、高度、线数目、周期等），防断栅栅线，外框，定位点，主栅等。
在步骤S600中，根据栅线的排布设计制作微结构模具，即根据栅线的排布设计，利用微接触纳米压印技术制作出微结构模具，该模具基底为PET，PC，PI，PMMA或者金属片材其中的一种材质。
在步骤S700中，对所述微结构模具表面进行金属化处理，即在模具结构面表面形成一层可导电的金属层，该层导电金属可以为：镍、铬、银、铜其中的一种材质。导电金属层可以采用物理气相沉积（PVD），银镜反应等方法制作而成。
在步骤S800中，对所述微结构模具表面的金属层进行电铸加厚，形成金属网，即将表面金属化的模具用电铸的工艺加厚其金属层，形成金属网，这里所用到的金属包括：镍，镍钴合金，铜，铜镍合金等。
进一步地，为了实现更好的转印效果，使栅线电极线型更细更均匀，采用上述金属网制作方法制作的金属网，其厚度为：0.001mm-0.1mm；厚度均匀性为：±0.003mm；锥度为：0锥度。此外，微结构通孔的侧壁完全平整，为镜面平整度，表面无凹凸或者坑洼，其翘曲度为：0翘曲度。
在采用上述金属网制作方法制作的金属网来进行太阳能电池电极的转印过程中，由于金属网具有钢性特质，并且金属网微结构通孔的侧壁平整，在转印过程中金属网与电池片非接触或微接触，从而使形成的栅线电极平直均匀，有益于减少浆料的损耗，继而降低生产成本；形成的太阳能电池由于栅线电极更细，从而可减少遮光面积，增大电流密度，提高能量转化效率。
本申请还提供一种太阳能电池，该太阳能电池包括由上述太阳能电池电极制作方法制作而成的电极，该电极的具体结构参照上述实施例，由于本太阳能电池采用了上述太阳能电池电极制作方法所有实施例的全部技术方案，因此至少具有上述实施例的技术方案所带来的所有有益效果，在此不再一一赘述。
需要说明，若本申请实施例中有涉及方向性指示（诸如上、下、左、右、前、后……），则该方向性指示仅用于解释在某一特定姿态下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。
另外，若本申请实施例中有涉及“第一”、“第二”等的描述，则该“第一”、“第二”等的描述仅用于描述目的，而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外，若全文中出现的“和/或”或者“及/或”，其含义包括三个并列的方案，以“A和/或B”为例，包括A方案、或B方案、或A和B同时满足的方案。另外，各个实施例之间的技术方案可以相互结合，但是必须是以本领域普通技术人员能够实现为基础，当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在，也不在本申请要求的保护范围之内。
根据上述说明书的揭示和教导，本申请所属领域的技术人员还可以对上述实施方式进行变更和修改。因此，本申请并不局限于上面揭示和描述的具体实施方式，对本申请的一些修改和变更也应当落入本申请的权利要求的保护范围内。此外，尽管本说明书中使用了一些特定的术语，但这些术语只是为了方便说明，并不对本申请构成任何限制。

Claims (14)

  1. 一种太阳能电池片电极制作方法，其中，所述方法包括如下步骤：
    将电池片间隔置于网版下方；
    将浆料放置于网版上；
    挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；及
    使浆料在电池片表面固化，形成电极；
    其中，所述网版包括网框、丝网、金属网、续料层，所述网版制作步骤包括：
    将所述金属网铺设于续料层上；
    将所述续料层与丝网贴合；及
    以一定的张力绷紧丝网，使丝网固定在网框上。
  2. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述方法还包括金属网制作步骤：
    根据太阳能电池片对金属网的栅线进行排布设计；
    根据栅线的排布设计制作微结构模具；
    对所述微结构模具表面进行金属化处理；及
    对所述微结构模具表面的金属层进行电铸加厚，形成金属网。
  3. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述栅线的横截面形状包括上下区域宽度具有一定关系的二元几何图形、上中下区域宽度具有多变的多元几何图形，其中，
    所述二元几何图形包括矩形、梯形、三角形、抛物线形；
    所述多元几何图形包括上宽中窄下宽或上窄中宽下窄的梯形、三角形、抛物线形。
  4. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述网版制作步骤还包括：
    将所述金属网通过粘接剂C与所述续料层粘合；
    将所述续料层通过粘接剂B与丝网粘合；及
    以一定的张力绷紧丝网，使丝网通过粘接剂A与所述网框粘合；
    其中，所述将所述金属网通过粘接剂C与所述续料层粘合的步骤还包括：
    将粘接剂C均匀涂覆于续料层上；
    待所述粘接剂C固化形成胶水层，在胶水层上用激光或者超声或者化学或者物理的方法刻画电池片栅线电极的图形；及
    使金属网与胶水层进行对位，在高温高压的条件下将金属网与续料层粘合；
    或者待粘接剂C固化形成胶水层后，将金属网直接放置于胶水层之上，在高温高压的条件下将金属网与续料层粘合，然后依据所需要的栅线图案，用激光透过金属网上的通孔，把胶水层刻穿，在胶水层上形成对应的栅线结构。
  5. 根据权利要求4所述的太阳能电池片电极制作方法，其中，还包括如下步骤：
    在续料层的另外一面涂上感光树脂或者感光乳剂，并且热烘烤固化；
    对位金属网的图形区域，用曝光显影的方式，在栅线区域之上形成特定的图形；其中，
    所述特定的图形包括漏斗形、矩形、梯形、半圆形，所述特定的图形宽度均大于或等于栅线的宽度。
  6. 根据权利要求4所述的太阳能电池片电极制作方法，其中，所述高温高压的条件为温度60摄氏度到250摄氏度之间，粘合的压力为8kg到200kg之间，保温保压时间为10至30分钟。
  7. 根据权利要求4所述的太阳能电池片电极制作方法，其中，
    所述粘接剂B采用环氧树脂型胶水、热熔胶、乳胶其中的一种材质，所述粘接剂B形态可为胶水或者胶膜；
    所述粘接剂C采用环氧树脂型胶水、热熔胶、UV胶、压敏胶、乳胶其中的一种材质，所述粘接剂C形态可为胶水或者胶膜；及
    所述粘接剂A采用热熔胶、乳胶其中的一种材质，所述粘接剂A形态可为胶水或者胶膜。
  8. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述续料层为网状编制结构复合层，所述网状编制结构复合层的目数范围为150目至650目，所述网状编制结构复合层采用钢、镍、镍钴合金、铜镍合金、玻纤网其中的一种或多种材质。
  9. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述制作的网版包括22.5 o的斜网网版和无网结网版。
  10. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述将电池片间隔置于网版下方；将浆料放置于网版上；挤压浆料，使浆料从网版的网孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；使浆料在电池片表面固化，形成电极的步骤还包括：
    将电池片间隔置于网版下方；
    将浆料均匀地填涂于续料层上；
    通过一定的压力将浆料挤压入金属网具有的微结构通孔中，使浆料根据所述微结构通孔的形状成型；
    驱动刮刀下压在续料层上，将更多的浆料挤入金属网中，使浆料从网版的微结构通孔中挤出且沉积于电池片表面，同时保持所述网版与电池片非接触/微接触；及
    将电池片放进太阳能电池烧结炉中进行烧结处理，使浆料在电池片表面固化，形成金属栅线电极。
  11. 根据权利要求10所述的太阳能电池片电极制作方法，其中，所述将电池片间隔置于网版下方的步骤包括：
    将电池片置于网版下方，调整金属网与电池片的间距，调整刮刀下压力以及浆料材质；
    其中，金属网与电池片的间距为金属网下表面与电池片之间的距离，该距离为0.03mm-2mm；及
    调整浆料材质包括调整浆料的组成成分以及浆料的粘稠度，所述浆料的组成成分包括银浆、铜浆、铝浆。
  12. 根据权利要求11所述的太阳能电池片电极制作方法，其中，所述金属网与电池片的间距为-500至-1600，所述覆墨刀与网版刮刀面的距离小于4mm，所述刮刀深度为1000至1600，所述刮刀压力为40N-70N。
  13. 根据权利要求1所述的太阳能电池片电极制作方法，其中，所述电极包括主栅线和副栅线，所述主栅线的宽度为0.03mm-1mm，所述主栅线的高度为0.013mm-0.1mm；所述副栅线宽度为0.005mm-0.03mm，所述细栅线的高度为0.005mm-0.04mm；所述主栅线和副栅线的形状包括矩形、三角形、梯形、抛物线形。
  14. 一种太阳能电池，其中，所述太阳能电池包括电极，所述电极采用如权利要求1-13中任一项太阳能电池片电极制作方法制作而成。
PCT/CN2021/105831 2021-07-02 2021-07-12 一种太阳能电池片电极制作方法及太阳能电池 WO2023272779A1 (zh)

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