Abstract:
A method of monolithically interconnecting electrical devices that isolates and interconnects the contacts of neighboring electrical devices such as thin film PV cells, without damaging the surrounding materials.

Description:
BACKGROUND 
     The invention relates generally to monolithic devices and more particularly to a method of monolithically interconnecting electrical devices such as photovoltaic (PV) cells on substrates including flexible substrates. 
     PV cells need to be electrically connected via an interconnection process in order for individual PV cells to be fabricated into modules. The conventional interconnection approach involves connecting discrete cells together via shingling or metallic ribbons. In the conventional approach, interconnected cells do not maintain a common substrate. 
     Monolithic integration refers to the process of interconnecting cells as part of the cell fabrication process. Monolithic integration typically is implemented for thin film PV modules where PV layers are deposited over large area substrates. Scribe and pattern steps are often used to divide the large area into electrically interconnected cells while maintaining a common substrate. This approach is typically applied to solar cells that are deposited on glass. 
     Several approaches exist for implementing monolithic integration; and each approach has various advantages and disadvantages related to the fabrication sequence, required tools, and material interactions, among other things. 
     One of the greatest challenges in thin film PV fabrication relates to the need to isolate the top contacts of neighboring cells, i.e., scribe through the top conducting outer layer without damaging the underlying layers. Three scribes are typically necessary to form a monolithic interconnect. The spacing between scribes should be wide enough to overcome the possibility of unwanted electrical connections. The total area occupied by the scribes plus any space between scribes should ideally be as small as possible to maximize the absorbing area of the PV cell. Mechanical scribing is not practical for flexible substrates; and laser scribing is challenging if the underlying layers are more highly absorbing than the overlying layer (in the case of CIS cells, the transparent conductive oxide (TCO) layer). 
     Thin film PV modules are implemented by dividing the module into individual cells that are series connected to provide a high voltage output. A conventional monolithic PV cell interconnect process employs a sequence of steps such as shown in  FIG. 3 . The process begins by depositing a first conducting layer  60  on a substrate  62 . The first conducting layer  60  is scribed using a linear cut  64  across the module. A semiconductor layer  66  such as a CIGS layer is then deposited as depicted in  FIG. 3 . A second scribe  68  parallel to the first scribe  64  isolates the CIGS layer  66  into individual PV cells. A second conducting layer  70  that may be a transparent conductive oxide (TCO) is then deposited as also depicted in  FIG. 3 . The process is completed with a third scribe  72  to form the series connection  74  in which the TCO from the second conducting layer  70  connects the top of one cell  76  to the bottom of the next cell  78 . 
     In view of the above, it would be both advantageous and beneficial to provide a method of monolithically interconnecting electrical devices such as PV cells on a common flexible substrate while avoiding the challenges associated with known monolithic integration techniques. 
     BRIEF DESCRIPTION 
     Briefly, in accordance with one embodiment, a monolithic module comprises: 
     a first conducting layer covering at least one semiconductor layer covering a second conducting layer covering a substrate; 
     a first trench penetrating through the first conducting layer to separate a first conducting layer for a first electrical device from a first conducting layer for a second electrical device; 
     a second trench penetrating through the at least one semiconductor layer and the second conducting layer to separate a second conducting layer for the first electrical device and a second conducting layer for the second electrical device, wherein the second trench is at least partially filled with a resistive material; 
     a third trench penetrating through the at least one semiconductor layer; and 
     an electrically conductive interconnecting material at least partially filling the third trench and providing an electrical current pathway from the first electrical device first conducting layer to the second electrical device second conducting layer. 
     A method of monolithically interconnecting electrical devices, the method comprising: 
     providing a first conducting layer covering at least one semiconductor layer covering a second conducting layer covering a substrate; 
     forming a first trench penetrating through at least the first conducting layer; 
     forming a second trench such that the second trench penetrates through at least one semiconductor layer and the second conducting layer; 
     forming a third trench such that the third trench penetrates through at least one semiconductor layer; 
     at least partially filling the first trench with a resistive material; 
     at least partially filling the third trench with an electrically conductive material such that it provides an electrical current pathway from the first electrical device first conducting layer to the second electrical device second conducting layer; 
     at least the second or third trenches are within the boundaries of the first trench. 
    
    
     
       DRAWINGS 
       These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is a diagram illustrating one cross sectional area of a monolithically integrated module according to one embodiment of the invention; 
         FIG. 2  is a diagram illustrating one cross sectional area of an electrical device suitable to implement the monolithic module shown in  FIG. 1 ; and 
         FIG. 3  illustrates a conventional interconnect process for a monolithically integrated module that is known in the art. 
     
    
    
     While the above-identified drawing figures set forth alternative embodiments, other embodiments of the present invention are also contemplated, as noted in the discussion. In all cases, this disclosure presents illustrated embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention. 
     DETAILED DESCRIPTION 
     The conventional interconnection approach for flexible devices to fabricating modules from individual electrical devices involves connecting discrete electrical devices together via shingling or metallic ribbons. Monolithic interconnection is the conventional approach on glass. Monolithic integration refers to the process of interconnecting the individual electrical devices together as part of the module fabrication process. Typically, monolithic integration is implemented for thin film PV modules where PV layers are deposited over large area substrates. Scribe and pattern steps are often used to divide the large area into electrically interconnected cells, as stated above, without dividing the substrate. 
     Although numerous approaches exist for implementing monolithic integration, each approach has its own set of advantages and disadvantages relating to, without limitation, the fabrication sequence, required tools, and interactions of materials. Keeping the foregoing in mind, an approach to monolithically connecting electrical devices such as PV cells that overcomes many of the disadvantages with known monolithic integration processes and devices is now described below with reference to the figures. 
     Looking now at  FIG. 1 , one cross section of a pair of monolithically interconnected electrical devices  10  is illustrated according to one embodiment of the invention. Although the invention is not so limited, the process described below with reference to  FIG. 1  is particularly useful for connecting copper indium gallium diselenide (CIGS) cells on flexible substrates or cells based on similar material systems. Other suitable semiconductor materials may include, without limitation, CdS, CdTe, amorphous silicon, Cu(In,Ga,Al)(S,Se)2, and micro-crystalline silicon. Suitable applications can include, without limitation, solar device applications and advanced OLED interconnection schemes in addition to improved fabrication or interconnection of low-cost or flexible electronics, optical devices, MEMS, microfluidics, medical, bio-sciences, sensing, or security devices and their combinations. 
     With continued reference to  FIG. 1 , the monolithically interconnected electrical devices  10  are formulated from a single device  50  such as depicted in  FIG. 2  that includes a first conducting layer  52  covering one or more semiconductor layers  54  covering a second conducting layer  56  covering a substrate  58 . The first conducting layer  52  may be a transparent conductive oxide such as, without limitation, doped versions of indium oxide, zinc oxide, or tin oxide. Other exemplary materials may include, without limitation, Al, Mo, SnO, CdSnO4, ZnSnO4, GaZnO, BZO, AZO, etc. Semiconductor layer(s)  54  may comprise, without limitation, CdS, CdTe, amorphous silicon, Cu(In,Ga,Al)(S,Se)2, micro-crystalline silicon, ZnS, or MgO. The second conducting layer  56  may comprise, without limitation, Al, Mo, ITO, ZnO, SnO, Cu, Au, Ag, etc. The semiconductor layer(s)  54  comprise copper indium gallium diselenide (CIGS) according to one aspect of the invention. The substrate  58  is a flexible substrate according to another aspect of the invention. The device structure for devices  10  shown in  FIG. 1  is particularly useful for connecting CIGS cells on a flexible substrate, as stated above. 
     Monolithically interconnected electrical devices  10  are formulated by first forming a first trench  12  penetrating through at least the first conducting layer  52  to provide a first conducting layer  14  for a first electrical device  40  and a different first conducting layer  16  for a second electrical device  42 . The first trench  12  may have a width between about 2 μm and about 300 μm, according to one aspect of the invention. A second trench  18  is formed within the first trench  12  such that the second trench  18  penetrates through the at least one semiconductor layer  54  and the second conducting layer  56  to provide a second conducting layer  20  for the first electrical device  40  and a different second conducting layer  22  for the second electrical device  42 . The width of the second trench  18  is smaller than the width of the first trench  12 . The second trench  12  may have a width between about 1 μm and about 100 μm, according to one aspect of the invention. A third trench  24  is also formed within the first trench  12  in proximity to the second trench  18 , such that the third trench  24  penetrates through the at least one semiconductor layer  54 . The second trench  18  and the third trench  24  can be formed in any order. The width of the third trench  24  is smaller than the width of the first trench  12 , and may have a width between about 1 μm and about 100 μm, according to one aspect of the invention. Spacing between the second trench  18  and the third trench  24  may lie in a range between about 0 μm and 100 μm. 
     The second trench  18  is filled with a resistive material  26  having a resistivity greater than about 10 Ohm-cm according to one aspect of the invention; and an electrically conductive interconnecting material  28  having a resistivity of less than about 10 −3  Ohm-cm according to one aspect of the invention, fills the third trench  24  and provides an electrical current pathway  30  from the first electrical device first conducting layer  14  to the second electrical device second conducting layer  22 . The electrically conductive interconnecting material  28  is patterned in such a way that it does not electrically connect the first conducting layers of neighboring electrical devices or cells. Suitable conductive polymers that may be used to provide the electrically conductive interconnecting material  28  may include, without limitation, polyaniline, polyacetylene, poly-3,4-ethylene dioxy thiophene (PEDOT), poly-3,4-propylene dioxythiophene (PProDOT), polystyrene sulfonate (PSS), polyvinyl carbazole (PVK), organometallic precursors, dispersions or carbon nanotubes, etc. 
     At least one of the trenches are at least partially filled by a liquid despense method such as, without limitation, ink-jet printing, screen printing, flexo printing, gravure printing, aerosol dispense, extrusion, syringe dispense, or any combination thereof. 
     Each device  40 ,  42  comprises a CIGS PV cell according to one aspect of the invention; while substrate  58  is a flexible substrate according to another aspect of the invention. 
     The monolithically interconnected electrical devices  10  advantageously can employ an interconnect material  28  that is different from that used to formulate the other device layers according to one aspect of the invention. Further, the process used to formulate the monolithically interconnected electrical devices  10  allows formation of trenches  12 ,  18 ,  24  after all device layers have been already deposited. The first conducting layer trench  12  also advantageously is used to make deeper trenches  18 ,  24  into the other device layers. 
     In summary explanation, a method of monolithically interconnecting electrical devices such as photovoltaic (PV) cells on a common substrate that may be a flexible substrate, has been described for fabricating a monolithically integrated module. The structure may avoid mechanical scribe steps, providing an advantage over known processing techniques for low cost flexible substrates. Since the interconnect processing can be implemented in one step after all device layers are deposited, the number of cleaning steps may be reduced, increasing the quality of device interfaces. Further, the interconnect area required for scribing can be reduced, thus providing a larger effective cell area to reduce the difference between individual device (cell) and module efficiency. 
     Those skilled in the monolithic device and related arts will readily understand the principles described above apply equally well to more complex structures including, without limitation, a full copper indium gallium diselenide (CIGS) device with p-n junctions and insulating intrinsic ZnO layers between the TCO and the window layers or other layers that may be included. Some other exemplary thin film semiconductor materials suitable for implementing PV modules and devices include hydrogenated amorphous silicon (a-Si:H) and cadmium telluride (CdTe), wherein for example, a-Si:H is used to make p-i-n homojunction cells and CdTe is used with CdS to make CdTe/CdS heterojunction cells. 
     Looking again at  FIG. 2 , some embodiments of second conducting layer  56  may comprise, for example, Al, Mo, ITO, ZnO, SnO Cu, Au, Ag, etc., while first conducting layer  52  may comprise, for example, tin oxide, indium oxide, indium tin oxide, zinc oxide (ZnO), or combinations thereof to provide transparent contacts in PV cells. Conducting layer  52  thus is transparent to portions of the light spectrum which are significantly absorbed by semiconductor material layer(s)  54 . 
     While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.