Patent ID: 8084684
Filing Date: 2011-12-27
Classification: G03G,H01L,H02S,Y02B,Y02E,Y02P,Y10T

Abstract:
1. A hexagonal prism three-dimensional monocrystalline silicon thin-film solar cell, comprising: a three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate with an area measuring at least 125 mm×125 mm and having a first set and a second set of structural surface topography features, wherein said thin-film comprises a thickness in the range of 2 to 30 microns; said first set of structural surface topography features positioned at predetermined locations on said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate and comprising a plurality of discrete and isolated hexagonal prism cavities having a central axis positioned substantially perpendicular to the light capturing surface of said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate, said discrete and isolated hexagonal prism cavities associated with a first 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; said second set of said structural surface topography features positioned at predetermined locations on said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate and comprising a plurality of interconnected continuous cavity boundary sidewalls defining said plurality of discrete and isolated hexagonal prism cavities thereby constructing said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate as a contiguous free-standing substrate, said boundary sidewalls associated with a second set of geometrical aspect ratios and dimensions comprising cavity boundary sidewall widths ranging at least approximately between 2 to 30 microns on the light capturing side of said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate; said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate, said first set of said structural surface topography features, and said second set of said structural surface topography features cooperating to comprise a free-standing, self-supporting three-dimensional monocrystalline silicon thin-film solar cell with sufficient mechanical rigidity for reduced cell breakage rate in a solar cell production factory; said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate having a sunlight capturing surface structure for enabling high solar cell conversion efficiency through efficient light trapping; an in-situ doped base region doped with a first dopant and formed within and comprising a substantial portion of said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate; a doped emitter region doped with a second dopant having a polarity opposite said first dopant and formed on at least a portion of a surface of said three-dimensional epitaxial monocrystalline silicon thin-film solar cell substrate, said base region and said emitter region forming an emitter-base junction structure; and metallization regions contacting at least portions of said in-situ doped base region and said doped emitter region.