N-TYPE SOLAR CELL AND SOLAR CELL ASSEMBLY COMPRISING THE SAME

An N-type solar cell including: an N-type silicon substrate, an emitter layer, a first tunneling layer, at least one first doped polysilicon layer, a passivation layer, a first anti-reflection coating, a second tunneling layer, at least one second doped polysilicon layer, and a second anti-reflection coating. The emitter layer is disposed on a front surface of the N-type silicon substrate. The first tunneling layer is disposed on the emitter layer. The at least one first doped polysilicon layer is disposed on the first tunneling layer. The passivation layer is disposed on the at least one first doped polysilicon layer. The first anti-reflection coating is disposed on the passivation layer. The second tunneling layer is disposed on a rear surface of the N-type silicon substrate. The at least one second doped polysilicon layer is disposed on the second tunneling layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. § 119 and the Paris Convention Treaty, this application claims foreign priority to Chinese Patent Application No. 202410606526.8 filed May 16, 2024, and to Chinese Patent Application No. 202421063495.8 filed May 16, 2024. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, MA 02142.

BACKGROUND

The disclosure relates to an N-type solar cell and a solar cell assembly comprising the same.

Conventional solar panel production involves: connecting multiple solar cells with interconnect ribbons to form solar strings; and then integrating the solar strings with other components to form a final solar panel. However, the production process lowers the overall efficiency of the solar cells for two main reasons: the interconnect ribbons take up space on the surface of the solar cells, reducing the effective light-receiving area of each solar cell; and gaps between adjacent solar cells within the solar strings are areas where there are no photovoltaic materials present, further reducing the effective light-receiving area.

P-type monocrystalline PERC (passivated emitter rear contact) solar cells have a theoretical limit to their conversion efficiency, which is 24.5%. Current industrial production lines achieve around 23.3% efficiency, which is close to the theoretical limit, leaving little room for significant improvement. However, challenges remain, particularly with light-induced degradation caused by boron-oxygen pairs in P-type silicon. The degradation limits further efficiency increases. In contrast, N-type cells, where electrons are the minority carriers, do not face the same degradation issues as P-type cells, where holes are minority carriers. In silicon wafers, impurities capture electrons more readily than holes. As a result, under the same conditions of metal impurity contamination, N-type cells exhibit lower surface recombination velocity and have minority carrier lifetimes that are 1-2 orders of magnitude higher than those of P-type cells. The extended lifetime enhances the open-circuit voltage and overall conversion efficiency of the N-type cells. Additionally, N-type silicon wafers have more uniform resistivity, resulting in a higher proportion of high-efficiency cells. The uniform resistivity across the substrate increases the high-efficiency output from the solar cells and enhances flexibility, potentially allowing for production of thinner silicon wafers.

The N-type silicon wafers are doped with phosphorus and have low boron content in crystalline silicon. The low boron content leads to minimal light-induced degradation caused by boron-oxygen pairs, almost reaching zero. As a result, the N-type silicon wafers experience less than 1% degradation in the first year, compared to the initial 2% degradation observed in P-type products. The N-type cells typically run at an average temperature about 0.5° C. lower than the P-type cells. The N-type cells have a lower temperature coefficient of −0.26% to −0.3% per degree Celsius, compared to −0.35% per degree Celsius for the P-type cells. The temperature coefficient difference means that the power output of the N-type cells decreases less as temperature increases, resulting in better overall performance and higher energy yield over time. The N-type cells have a superior response to weak light conditions, generating electricity even when irradiance is below 400 W/m2. The superior response is particularly beneficial during early morning, evening, or overcast weather when sunlight is less intense. The N-type cells typically have an 85% bifacial coefficient compared to 70% for P-type PERC cells, resulting in approximately 3% additional electricity gain for end-users under standard ground reflectivity conditions. N-type high-efficiency solar cell technology, characterized by high conversion efficiency, low temperature coefficient, and reduced degradation from PID (Potential Induced Degradation), LID (Light-Induced Degradation), and LeTID (Light and Elevated Temperature Induced Degradation), is gaining significant attention and recognition in the industry. As a result, there is a trend towards replacing the P-type cells with N-type solutions. However, challenges persist in the application and production of the N-type cells.

The challenges describe above impact the efficiency of assembling the solar cells into module products. The potential for further cost reduction has reached its limit, creating obstacles for the application and development of the N-type high-efficiency solar cell technology.

SUMMARY

To solve the aforesaid problems, the first objective of the disclosure is to provide an N-type solar cell and a solar cell assembly comprising the same.

The N-type solar cell comprises an N-type silicon substrate, an emitter layer, a first tunneling layer, at least one first doped polysilicon layer, a passivation layer, a first anti-reflection coating, a second tunneling layer, at least one second doped polysilicon layer, and a second anti-reflection coating. The emitter layer is disposed on a front surface of the N-type silicon substrate; the first tunneling layer is disposed on the emitter layer; the at least one first doped polysilicon layer is disposed on the first tunneling layer; the passivation layer is disposed on the at least one first doped polysilicon layer; the first anti-reflection coating is disposed on the passivation layer; the second tunneling layer is disposed on a rear surface of the N-type silicon substrate; the at least one second doped polysilicon layer is disposed on the second tunneling layer; and the second anti-reflection coating is disposed on the at least one second doped polysilicon layer.

In a class of this embodiment, the N-type solar cell further comprises a plurality of first fingers and a plurality of second fingers; the plurality of first fingers are disposed on an outer side of the first anti-reflection coating; and the plurality of second fingers are disposed on an outer side of the second anti-reflection coating.

In a class of this embodiment, the first tunneling layer and the second tunneling layer comprise silicon dioxide.

In a class of this embodiment, the passivation layer comprises aluminum oxide.

The second objective of the disclosure is to provide a solar cell assembly. The solar cell assembly comprises at least one solar array. The at least one solar array comprises a plurality of solar cell strings connected in series and/or in parallel. Each of the plurality of solar cell strings comprises a first carrier film, a second carrier film, a plurality of low-temperature interconnect ribbons, and a plurality of N-type solar cells. The plurality of N-type solar cells are disposed side by side. Every two adjacent N-type solar cells are interconnected using one of the plurality of low-temperature interconnect ribbons. Specifically, one end of one of the plurality of low-temperature interconnect ribbons is connected to the front surface of one of the plurality of N-type solar cells, and the other end of the low-temperature interconnect ribbon is connected to the rear surface of the adjacent N-type solar cell. The first carrier film is disposed on the front surface of each of the plurality of N-type solar cells. The second carrier film is disposed on the rear surface of each of the plurality of N-type solar cells. The plurality of low-temperature interconnect ribbons are adhered to the first carrier film and the second carrier film, thereby forming the plurality of solar cell strings. The solar cell assembly further comprises a plurality of ribbons. The plurality of ribbons are disposed between the plurality of solar cell strings to collect and conduct electricity. The arrangement forms the at least one solar array.

In a class of this embodiment, the solar cell assembly further comprises a first encapsulant film, a second encapsulant film, a first sheet, and a second sheet. The first encapsulant film is disposed on a front surface of the at least one solar array. The second encapsulant film is disposed on a rear surface of the at least one solar array. The first sheet is disposed on the first encapsulant film, and the second sheet is disposed on the second encapsulant film.

In a class of this embodiment, the solar cell assembly further comprises a split-type junction box disposed on the second sheet.

In a class of this embodiment, the solar cell assembly further comprises a first frame and a second frame. A short edge of the at least one solar array is encapsulated with the first frame, and a long edge of the at least one solar array is encapsulated with the second frame.

In a class of this embodiment, the plurality of low-temperature interconnect ribbons are a plurality of low-temperature alloy copper wires.

The following advantages are associated with the disclosure:

DETAILED DESCRIPTION

As shown in FIGS. 1-2, an N-type solar cell comprises an N-type silicon substrate 1, an emitter layer 2, a first tunneling layer 3, at least one first doped polysilicon layer 4, a passivation layer 7, a first anti-reflection coating 8, a second tunneling layer 5, at least one second doped polysilicon layer 6, and a second anti-reflection coating 9. The emitter layer is disposed on a front surface of the N-type silicon substrate; the first tunneling layer 3 is disposed on the emitter layer; the at least one first doped polysilicon layer 4 is disposed on the first tunneling layer 3; the passivation layer 7 is disposed on the at least one first doped polysilicon layer 4; the first anti-reflection coating 8 is disposed on the passivation layer 7; the second tunneling layer 5 is disposed on a rear surface of the N-type silicon substrate; the at least one second doped polysilicon layer 6 is disposed on the second tunneling layer 5; and the second anti-reflection coating 9 is disposed on the at least one second doped polysilicon layer 6.

The N-type solar cell further comprises a plurality of first fingers 10 and a plurality of second fingers 11. The plurality of first fingers 10 are disposed on an outer side of the first anti-reflection coating 8. The plurality of second fingers 11 are disposed on an outer side of the second anti-reflection coating 9. Specifically, the plurality of first fingers 10 are printed on the first anti-reflection coating 8, and the plurality of second fingers 11 are disposed on the second anti-reflection coating 9; subsequently, the plurality of first fingers 10 and the plurality of second fingers 11 are subjected to a sintering process; the sintering process causes the plurality of first fingers 10 and the plurality of second fingers 11 to penetrate the first anti-reflection passivation layer 8 and the anti-reflection passivation layer 9, respectively, thereby forming an ohmic contact with the at least one first doped polysilicon layer 4 and the at least one second doped polysilicon layer 6; following the sintering process, light injection is performed; and then a light-receiving surface of the N-type solar cell is sintered using a laser and a reverse voltage.

The first tunneling layer 3 and the second tunneling layer 5 comprise silicon dioxide. The passivation layer 7 comprises aluminum oxide. The at least one first doped polysilicon layer 4 comprises an n+ polysilicon film.

As shown in FIGS. 3-7, a solar cell assembly comprises a plurality of at least one solar array. The at least one solar array comprises a plurality of solar cell strings connected in series and/or in parallel. Each of the plurality of solar cell strings comprises a first carrier film 12.1, a second carrier film 12.2, a plurality of low-temperature interconnect ribbons 13, and a plurality of N-type solar cells 14. The plurality of N-type solar cells are disposed side by side. Every two adjacent N-type solar cells are interconnected using one of the plurality of low-temperature interconnect ribbons 13. Specifically, one end of one of the plurality of low-temperature interconnect ribbons 13 is connected to the front surface of one of the plurality of N-type solar cells, and the other end of the same low-temperature interconnect ribbon is connected to the rear surface of the adjacent N-type solar cell. The arrangement allows for alternating connection of positive electrodes and negative electrodes.

The first carrier film 12.1 is disposed on the front surface of each of the plurality of N-type solar cells 14. The second carrier film 12.2 is disposed on the rear surface of each of the plurality of N-type solar cells. The plurality of low-temperature interconnect ribbons 13 are adhered to the first carrier film and the second carrier film, thereby forming the plurality of N-type solar cell strings.

The solar cell assembly further comprises a plurality of ribbons 20; the plurality of ribbons 20 are disposed between the plurality of solar cell strings 17 to collect and conduct electricity. The arrangement forms the at least one solar array. The solar cell assembly further comprises a first encapsulant film 15.1, a second encapsulant film 15.2, a first sheet 16.1, and a second sheet 16.2. The first encapsulant film 15.1 is disposed on a front surface of the at least one solar array. The second encapsulant film 15.2 is disposed on a rear surface of the at least one solar array. The first sheet 16.1 is disposed on the first encapsulant film 15.1, and the second sheet 16.2 is disposed on the second encapsulant film 15.2.

The solar cell assembly further comprises a split-type junction box 18 disposed on the second sheet 16.2.

The solar cell assembly further comprises a first frame 19.1 and a second frame 19.2. A short edge of the at least one solar array is encapsulated with the first frame 19.1, and a long edge of the at least one solar array is encapsulated with the second frame 19.2.

The plurality of low-temperature interconnect ribbons are a plurality of low-temperature alloy copper wires.

The following advantages are associated with the disclosure:

The improvements collectively reduce electrical losses when the N-type solar cells are assembled into a solar cell assembly, achieving over 101% CTM efficiency (including contributions from double-sided coated glass (+0.5%), half-cut cells (+0.2%), 0BB technology (+1%), light conversion films (+0.3%), and reflective films (+0.3%)). The enhancement results in higher power per unit area and lower product costs. Additionally, the reliability of the N-type solar cell is improved, with first-year degradation limited to ≤1% and linear annual degradation <0.4%.