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New Solar Cells?

Patent

US8129822B2

Owner

Beamreach Solar Inc.

Filing Date

October 06, 2007

Priority Date

December 06, 2012

Portfolio

Solar - Beamreach

Intro

Read about this template for three-dimensional thin-film solar cell manufacturing and its methods of use. Is this a real innovation or just an improvement? Leave your comments! 

Claims

1. A structure for use in the fabrication of a photovoltaic solar cell, said structure comprising; a reusable monocrystalline silicon template; a subs...
  1. A structure for use in the fabrication of a photovoltaic solar cell, said structure comprising; a reusable monocrystalline silicon template; a substantially conformal sacrificial porous silicon layer coupled to said reusable template; and an epitaxial three-dimensional monocrystalline silicon thin-film solar cell substrate deposited on said conformal sacrificial porous silicon layer; wherein said reusable template has an area at least as large as an area of said three-dimensional monocrystalline silicon thin-film solar cell substrate, said three-dimensional monocrystalline silicon thin-film solar cell substrate measuring at least 125 mm×125 mm, said reusable template having an array of structural surface topography features substantially conforming to desired structural surface topography features of said three-dimensional monocrystalline thin-film solar cell substrate; and further wherein a first subset of said structural surface topography features are positioned at predetermined locations on said template and comprise a plurality of discrete and isolated hexagonal posts defined by sidewalls and having a central axis positioned substantially perpendicular to a top surface of said reusable template, said discrete and isolated hexagonal posts associated with a set of geometrical aspect ratios and dimensions comprising a ratio between height and hexagonal diagonal dimension approximately in the range of 0.5 to 5.0; and a second subset of said structural surface topography features are positioned at predetermined locations on said template and comprise a plurality of interconnected continuous trenches interspersed among and bordering said plurality of discrete and isolated hexagonal posts and having a trench bottom width ranging at least approximately between 1 to 30 microns; said three-dimensional monocrystalline silicon thin-film solar cell substrate having a surface topography defined by said first and said second subset of said structural surface topography features of said reusable template; said reusable template, said first subset of said structural surface topography features, and said second subset of said structural surface topography features cooperating to ensure that said three-dimensional monocrystalline silicon thin-film solar cell substrate is capable of being detached from said reusable template as a free-standing, self-supporting substrate with sufficient mechanical rigidity and resilience for processing in a solar cell manufacturing environment; and said reusable template further configured to form in said three-dimensional monocrystalline silicon thin-film solar cell substrate a sunlight capturing surface structure for enabling high solar cell conversion efficiencies.
  2. The structure of claim 1, wherein said sidewalls of said hexagonal posts are tapered sidewalls with sidewall angles in the range of 0° to 10°. 
  3. The structure of claim 1, wherein said plurality of interconnected continuous trenches further comprise backside holes providing access to said trenches from a backside of said template. 
  4. The structure of claim 1, wherein said plurality of interconnected continuous trenches are through-wafer trenches. 
  5. The structure of claim 1, wherein said set of geometrical aspect ratios comprise a ratio between height and hexagonal diagonal dimension are approximately in the range of 1 to 3. 
     
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Abstract

A template 100 for three-dimensional thin-film solar cell substrate formation for use in three-dimensional thin-film solar cells. The templa...
A template 100 for three-dimensional thin-film solar cell substrate formation for use in three-dimensional thin-film solar cells. The template 100 comprises a substrate which comprises a plurality of posts 102 and a plurality of trenches 104 between said plurality of posts 102. The template 100 forms an environment for three-dimensional thin-film solar cell substrate formation.
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