Patent Description:
Solar cells have good photoelectric conversion capabilities. In solar cells, a diffusion process is required on the surface of silicon wafers to produce p-n junctions. In existing solar cells, boron diffusion processes are usually performed on the surface of silicon wafers to form an emitter on the surface of silicon wafers. On one hand, the emitter forms a p-n junction with the silicon wafer, and on the other hand, the emitter is also electrically connected with a metal electrode, so that the carriers transporting in the emitter can be collected by the metal electrode. Therefore, the emitter has a great influence on the photoelectric conversion performance of the solar cells.

The photoelectric conversion performance of the existing solar cells is poor.

<NPL> discloses high-efficiency solar cells with passivating rear contact were fabricated on n-type high-performance multi crystalline silicon.

Embodiments of the present disclosure provide a solar cell and a production method thereof, and a photovoltaic module, which is at least conducive to the improvement of photoelectric conversion performance of a solar cell.

One or more embodiments are exemplarily illustrated in reference to corresponding accompanying drawing(s), and these exemplary illustrations do not constitute limitations on the embodiments. Unless otherwise stated, the accompanying drawings do not constitute scale limitations.

It can be known from the background art that the existing solar cells have a poor photoelectric conversion performance.

By analysis, it is found that one of the reasons for the poor photoelectric conversion performance of the existing solar cells is that the emitter is usually electrically connected to a metal electrode, so that the metal electrode can collect carriers in the emitter. In order to reduce the contact resistance between the metal electrode and the emitter, the sheet resistance of the emitter should be reduced. At present, in order to reduce the sheet resistance of the emitter, the doping concentration of the emitter is usually increased. However, when the doping concentration of the emitter increases, the doping element in the emitter becomes too much, so that the doping element in the emitter becomes a strong recombination center, causing the increase of Auger recombination. Thus, the passivation performance of the emitter deteriorates, which in turn makes the photoelectric conversion performance of the solar cell to be poor.

Embodiments of the present disclosure provide a solar cell, including a P-type emitter formed on a first surface of an N-type substrate, first pyramid structures are formed on a top surface of a first portion of the P-type emitter, a transition surface is respectively formed on at least one edge of each first pyramid structure, the transition surface is joined with two adjacent inclined surfaces of the each first pyramid structure, and the transition surface is concave or convex relative to a center of the each first pyramid structure, a substructure is formed on each of top surfaces of at least a part of the first pyramid structures, in other words, each of at least a part of the first pyramid structures has a micro-defect. Such micro-defect can form a certain crystal change, thereby forming a defect energy level, so that the doping concentration of the first portion of the P-type emitter can be kept low while the sheet resistance of the first portion of the P-type emitter can be greatly reduced. In this way, the generation of Auger recombination can be reduced, and the photoelectric conversion performance of the solar cell can be improved. Moreover, edges of each second pyramid structure of the second portion of the P-type emitter are linear, in other words, each second pyramid structure is a normal pyramid structure. In this way, the sheet resistance of the second portion of the P-type emitter can be relatively high, thereby reducing the generation of recombination centers and improving the open-circuit voltage and short-circuit current of the solar cell.

Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. Those skilled in the art should understand that, in the embodiments of the present disclosure, many technical details are provided for the reader to better understand the present disclosure. However, even without these technical details and various modifications and variants based on the following embodiments, the technical solutions claimed in the present disclosure can be realized.

<FIG> is a structural schematic diagram of a solar cell according to an embodiment of the present disclosure, <FIG> is a partial enlarged view of the part marked with reference numeral "<NUM>" in <FIG>, <FIG> is another partial enlarged view of the part marked with the reference numeral "<NUM>" in <FIG>, <FIG> is still another partial enlarged view of the part marked with the reference numeral "<NUM>" in <FIG>, and <FIG> is a partial enlarged view of the part marked with reference numeral "<NUM>" in <FIG>.

Referring to <FIG>, the solar cell includes: an N-type substrate <NUM>; a P-type emitter <NUM> formed on a first surface of the N-type substrate <NUM>, the P-type emitter <NUM> includes a first portion <NUM> and a second portion <NUM>, first pyramid structures <NUM> are formed on a top surface of the first portion <NUM>, and second pyramid structures <NUM> are formed on a top surface of the second portion <NUM>, a transition surface <NUM> is respectively formed on at least one edge of each first pyramid structure <NUM>, the transition surface <NUM> is joined with two adjacent inclined surfaces of the each first pyramid structure <NUM>, and the transition surface <NUM> is concave or convex relative to a center of the each first pyramid structure <NUM>, a substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, and a shape of the substructure <NUM> is spherical or spherical-like, edges of each second pyramid structure <NUM> are linear, and a sheet resistance of the first portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, a doping concentration at the top surface of the first portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>, a sheet resistance of the second portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the second portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>; and a tunnel layer <NUM> and a doped conductive layer <NUM> sequentially formed over a second surface of the N-type substrate <NUM> in a direction away from the N-type substrate <NUM>.

The N-type substrate <NUM> is used to receive incident light and generate photogenerated carriers. In some embodiments, the N-type substrate <NUM> may be an N-type silicon substrate <NUM>, and the material of the N-type silicon substrate may include at least one of monocrystalline silicon, polycrystalline silicon, amorphous silicon or microcrystalline silicon. The N-type substrate <NUM> is an N-type semiconductor substrate <NUM>, that is, the N-type substrate <NUM> is doped with N-type dopant ions, and the N-type dopant ions may be any one of phosphorus ions, arsenic ions, or antimony ions.

In some embodiments, the solar cell may be configured as a tunnel oxide passivated contact (TOPCON) cell. The first surface and the second surface of the N-type substrate <NUM> are arranged opposite to each other, and both the first surface and the second surface of the N-type substrate <NUM> can be used to receive incident light or reflected light. In some embodiments, the first surface may be the back surface of the N-type substrate <NUM>, and the second surface may be the front surface of the N-type substrate <NUM>. In some other embodiments, the first surface may be the front surface of the N-type substrate <NUM>, and the second surface may be the back surface of the N-type substrate <NUM>.

In some embodiments, the second surface of the N-type substrate <NUM> may be designed as a pyramid textured surface, so that the reflectivity of the second surface of the N-type substrate <NUM> to incident light is low, therefore the absorption and utilization rate of light is high. The first surface of the N-type substrate <NUM> may be designed as a non-pyramid textured surface, such as in a stacked step form, so that the tunnel oxide layer <NUM> located on the first surface of the N-type substrate <NUM> has high density and uniformity, therefore the tunnel oxide layer <NUM> has a good passivation effect on the first surface of the N-type substrate <NUM>. In some embodiments, the first surface may be the back surface of the N-type substrate <NUM>, and the second surface may be the front surface of the N-type substrate <NUM>. In some other embodiments, the first surface may be the front surface of the N-type substrate <NUM>, and the second surface may be the back surface of the N-type substrate <NUM>.

Referring to <FIG>, the transition surface <NUM> is respectively formed on at least one edge of each first pyramid structure <NUM>. It should be understood that an edge refers to a strip-like bulge portion of a first pyramid structure <NUM>, i.e., a portion where adjacent inclined surfaces join of the first pyramid structure <NUM>, and not only literally means "line". In an example, a first pyramid structure has a bottom surface and a plurality of inclined surfaces joined with the bottom surface, two adjacent inclined surfaces join with each other, and a transition surface <NUM> is formed between the two adjacent inclined surfaces, that is to say, at least parts of the two adjacent inclined surfaces join with each other via the transition surface <NUM>. In some embodiments, a transition surface <NUM> is formed on one edge of a first pyramid structure <NUM>, and the transition surface <NUM> may only be formed on a part of the edge, or may be formed on the entire edge. That is to say, two adjacent inclined surfaces of the first pyramid structure <NUM> are connected by the transition surface <NUM>. In some other embodiments, a transition surface <NUM> is respectively formed on a plurality of edges of a first pyramid structure <NUM>, and the transition surfaces <NUM> may only be formed on a part of an edge, or may be formed on the entire edge. The embodiments of the present disclosure do not limit the specific position of the transition surface <NUM> on an edge, as long as the transition surface <NUM> is formed on the edge.

It should be understood that the first pyramid structures <NUM> and the second pyramid structures <NUM> here are different from the textured structure. In the embodiments of the present disclosure, the silicon crystal morphology of the first portion <NUM> of the P-type emitter <NUM> is changed by forming the first pyramid structures <NUM> and the second pyramid structures <NUM> on the surface of the P-type emitter <NUM>, thereby changing the performance of the first portion <NUM> of the P-type emitter <NUM>.

As an example, a transition surface <NUM> is respectively formed on at least one edge of each first pyramid structure <NUM>, i.e. the at least one edge of each first pyramid structure <NUM> has irregular deformation, and a spherical or spherical-like substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, so that the first pyramid structures <NUM> have micro-defects, and changes in silicon crystals are formed in the first portion <NUM> of the P-type emitter. Furthermore, edges of each second pyramid structure <NUM> are linear, in other words, there is no deformation in the edges of each second pyramid structure <NUM>. Due to the deformation in the at least one edge of each first pyramid structure <NUM> and the deformation in each of top surfaces of at least a part of the first pyramid structures <NUM>, a sheet resistance of the first portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the first portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>. Since there is no deformation in the edges of each second pyramid structure <NUM>, a sheet resistance of the second portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the second portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>. It is obvious that the sheet resistance of the first portion <NUM> is much less than the sheet resistance of the second portion <NUM>, but the doping concentration at the top surface of the first portion <NUM> is not much different from the doping concentration at the top surface of the second portion <NUM>. It can be seen that due to the micro-defects of the first pyramid structures <NUM>, the sheet resistance of the first portion <NUM> is much less than the sheet resistance of the second portion <NUM>, thereby greatly improving ohmic contact of the first portion <NUM> of the P-type emitter <NUM>. Meanwhile, the doping concentration of the first portion <NUM> of the P-type emitter <NUM> is kept low, so that the generations of recombination centers in the first portion <NUM> of the P-type emitter <NUM> can be reduced, the good passivation effect of the P-type emitter <NUM> can be maintained, and the generations of Auger recombination can be reduced. In this way, the photoelectric conversion performance of the solar cell can be improved. In some embodiments, heights of the first pyramid structures <NUM> range from <NUM> to <NUM>, and one-dimensional sizes of the bottoms of the first pyramid structures <NUM> range from <NUM> to <NUM>. It should be understood that the larger the heights and the one-dimensional sizes of the bottoms of the first pyramid structures <NUM> in the first portion <NUM> of the P-type emitter <NUM> are, the larger the overall sizes of the first pyramid structures <NUM> are, so that in a unit area, a number of the first pyramid structures <NUM> in the first portion <NUM> of the P-type emitter <NUM> is smaller. The smaller the number of the first pyramid structures <NUM>, the fewer the first pyramid structures with micro-defects, so that degree of the crystal deformation generated in the first portion <NUM> of the P-type emitter <NUM> is lower. Correspondingly, the smaller the sizes of the first pyramid structures <NUM> is, the greater the number of the first pyramid structures <NUM> in the first portion <NUM> of the P-type emitter <NUM> per unit area, so that degree of the crystal deformation generated in the first portion <NUM> of the P-type emitter <NUM> is higher. Based on this, the heights of the first pyramid structures <NUM> are set in a range of <NUM> to <NUM>, and the one-dimensional sizes of the bottoms of the first pyramid structures <NUM> are set in a range of <NUM> to <NUM>. In this way, on one hand, the number of the first pyramid structures <NUM> is relatively great, and the degree of the crystal deformation generated in the first portion <NUM> of the P-type emitter <NUM> is relatively high, so that a relatively high defect energy level is obtained, thereby leading to a lower sheet resistance of the first portion <NUM> of the P-type emitter <NUM>, and improving the ohmic contact. On the other hand, within this range, excessive number of the first pyramid structures <NUM> in the first portion <NUM> of the P-type emitter <NUM> can be avoided, which can prevent the problem of forming an excessively high defect energy level, thereby forming strong recombination centers in the P-type emitter <NUM>. In this way, the passivation performance of the first portion <NUM> of the P-type emitter <NUM> can be improved.

Referring to <FIG> and <FIG>, a substructure <NUM> is further formed on each of at least a part of the first pyramid structures <NUM>. The existence of the substructures <NUM> makes the degree of the micro-defects in the first pyramid structures <NUM> higher, so that the defect energy level formed in the first portion <NUM> of the P-type emitter is higher, thereby further reducing the sheet resistance of the first portion <NUM> of the P-type emitter <NUM>.

Referring to <FIG> and <FIG>, each edges of the second pyramid structure <NUM> on the top surface of the second portion <NUM> are designed to be linear, in other words, in each second pyramid structure <NUM>, two adjacent inclined surfaces are directly joined, and no deformation occurs on the edges, so that a second pyramid structure <NUM> is a regular tetrahedron structure. That is to say, in the second portion <NUM> of the P-type emitter <NUM>, no change occurs in the crystal structure. Thus, no defect energy level is formed in the second portion <NUM> of the P-type emitter <NUM>, thereby not only leading to a relatively high sheet resistance of the second portion <NUM> of the P-type emitter <NUM>, but also preventing the formation of a large number of recombination centers in the second portion <NUM> of the P-type emitter <NUM>. In this way, a good passivation performance of the second portion <NUM> of the P-type emitter <NUM> can be maintained, the open-circuit voltage and short-circuit current of the solar cell can be relatively high, and photoelectric conversion performance of the solar cell can be improved.

Referring to <FIG>, in some embodiments, based on the differences between the first pyramid structures <NUM> and the second pyramid structures <NUM>, the sheet resistance of the first portion <NUM> may be lower than the sheet resistance of the second portion <NUM>. Since the edge(s) of a first pyramid structure <NUM> deforms, and at least a part of the first pyramid structures <NUM> further include substructures <NUM>, defect energy level is formed in the first portion <NUM> of the P-type emitter <NUM>, so that the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> is low. While, the edges of each second pyramid structure <NUM> does not deform, so that no defect energy level is formed in the second portion <NUM> of the P-type emitter <NUM>. Thus, the second portion <NUM> of the P-type emitter <NUM> has a relatively high sheet resistance. In some embodiments, the sheet resistance of the first portion <NUM> may be 10ohm/sq~50ohm/sq, 50ohm/sq~75ohm/sq, 75ohm/sq~100ohm/sq, 100ohm/sq~150ohm/sq, 150ohm/sq~200ohm/sq, 200ohm/sq~300ohm/sq, 300ohm/sq~400ohm/sq or 400ohm/sq~500ohm/sq. The sheet resistance of the second portion <NUM> may be 100ohm/sq~200ohm/sq, 200ohm/sq~300ohm/sq, 300ohm/sq~400ohm/sq, 400ohm/sq~500ohm/sq, 500ohm/sq~700ohm/sq, 700ohm/sq~850ohm/sq, 850ohm/sq~1000ohm/sq. The sheet resistance of the first portion <NUM> of the P-type emitter <NUM> is much lower than that of the second portion <NUM>, thus an improved ohmic contact of the first portion <NUM> of the P-type emitter <NUM> can be obtained, which can reduce the contact resistance between the first portion <NUM> of the P-type emitter <NUM> and the metal electrode when the metal electrode is arranged to be in an electrical contact with the first portion <NUM> of the P-type emitter <NUM>, thereby improving the transport efficiency of carriers in the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM>. In addition, by setting the resistance of the second portion <NUM> of the P-type emitter <NUM> to 100ohm/sq~1000ohm/sq, the recombination of carriers in the second portion <NUM> of the P-type emitter <NUM> can be suppressed. In some embodiments, a recombination current in the second portion <NUM> of the P-type emitter <NUM> is below 20fA/cm<NUM>, relatively low recombination current is conducive to reduction of recombination of carriers, thereby improving the passivation effect of the emitter. In this way, the open-circuit voltage, the short-circuit current and the photoelectric conversion efficiency of the solar cell can be improved.

In some embodiments, the junction depth of the first portion <NUM> is not less than that of the second portion <NUM>, that is to say, a thickness of the first portion <NUM> is relatively large. Thus, an electrical connection can be provided between the metal electrode and the first portion <NUM> of the P-type emitter <NUM>, so that the problem that the paste for forming the metal electrode penetrates the P-type emitter <NUM> and directly contacts with the N-type initial substrate <NUM> during the sintering of the paste can be prevented. In addition, the junction depth of the second portion <NUM> is designed to be shallower, that is, a thickness of the second portion <NUM> of the P-type emitter <NUM> is relatively small, so that the number of doping elements in the second portion <NUM> is less than the number of doping elements in the first portion <NUM>, in other words, the doping concentration of the second portion <NUM> of the P-type emitter <NUM> is lower. Therefore, compared with the first portion <NUM> of the P-type emitter <NUM>, the second portion <NUM> of the P-type emitter <NUM> has a better passivation effect, which is conducive to reduction of the recombination of carriers and improvement of the open-circuit voltage and short-circuit current of the solar cell.

In some embodiments, a ratio of the junction depth of the first portion <NUM> to the junction depth of the second portion <NUM> is not less than <NUM>. As an example, the ratio of the junction depth of the first portion <NUM> to the junction depth of the second portion <NUM> ranges from <NUM> to <NUM>. For example, the ratio can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>. The junction depth of the first portion <NUM> is much deeper than that of the second portion <NUM>, so that the junction depth of the first portion <NUM> of the P-type emitter <NUM> is deeper. In this way, when the metal electrode is electrically connected with the first portion <NUM> of the P-type emitter <NUM>, it can be ensured that the paste will not burn through the first portion <NUM> of the p-type emitter <NUM> during the sintering, so as to prevent the problem of damaging the p-n junction due to the contact between the metal electrode and the N-type substrate <NUM>, thereby ensuring good photoelectric conversion performance of the solar cell.

In some embodiments, the junction depth of the first portion <NUM> ranges from <NUM> to <NUM>, and the junction depth of the second portion <NUM> ranges from <NUM> to <NUM>. Within this range, the junction depth of the first portion <NUM> is not too deep, so as to avoid the problem that content of doping element in the first portion <NUM> of the P-type emitter <NUM> is too high due to excessive thickness of the first portion <NUM> to form a strong recombination center. Moreover, within this range, the junction depth of the second portion <NUM> is relatively shallow, and there are relatively few doping elements in the second portion <NUM> of the P-type emitter <NUM>, so that a good passivation effect of the P-type emitter <NUM> can be maintained.

In some embodiments, a doping element in the first portion <NUM> of the P-type emitter <NUM> is of a same conductivity type as a doping element in the second portion <NUM> of the P-type emitter <NUM>, and the doping element in the first portion <NUM> and the doping element in the second portion <NUM> are each a trivalent element. In other words, each of the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM> includes only one of the trivalent elements, i.e. the first portion <NUM> and the second portion <NUM> are doped with a single element. Thus, the first portion <NUM> and the second portion <NUM> of the P-type emitter <NUM> include no impurity element, thereby preventing the problem of carrier recombination due to impurity elements becoming recombination centers.

In some embodiments, the doping element in the first portion <NUM> and the doping element in the second portion <NUM> each include boron element or gallium element. The first portion <NUM> and the second portion <NUM> are designed to include only one kind of doping element, so that the first portion <NUM> and the second portion <NUM> of the P-type emitter <NUM> become high-efficiency doping layers, thus there is no impurity element in the first portion <NUM> and the second portion <NUM> of the P-type emitter <NUM>, or an amount of the impurity element is very small. In this way, the problem of the impurity element becoming a recombination center can be avoided, thereby suppressing the recombination of carriers and increasing the number of carriers.

In some embodiments, the doping concentration at the top surface of the first portion <NUM> is not less than the doping concentration at the top surface of the second portion <NUM> of the P-type emitter <NUM>. Since the junction depth of the first portion <NUM> is larger than that of the second portion <NUM>, the first portion <NUM> of the P-type emitter <NUM> includes more doping elements. In some embodiments, the doping concentration at the top surface of the first portion <NUM> may be 1E<NUM>atoms/cm<NUM> to 7E<NUM>atoms/cm<NUM>, 7E<NUM>atoms/cm<NUM> to 1E<NUM>atoms/cm<NUM>, 1E<NUM>atoms/cm<NUM> to 6E<NUM>atoms/cm<NUM>, 6E<NUM>atoms/cm<NUM> to 1E<NUM>atoms/ cm<NUM> or 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>; and the doping concentration at the top surface of the second portion <NUM> may be 1E<NUM>atoms/cm<NUM> to 1E<NUM>atoms/cm<NUM>, 1E<NUM>atoms/cm<NUM> to 1E<NUM>atoms/cm<NUM>, 1E<NUM>atoms/cm<NUM> to 1E<NUM>atoms/cm<NUM> or 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>. The doping concentration at the top surface of the first portion <NUM> is designed to be relatively high, which can ensure that the sheet resistance of the first portion <NUM> is relatively low. Meanwhile, the doping concentration at the top surface of the second portion <NUM> is designed to be relatively low, which can avoid that excessive doping elements become recombination centers due to there being too many doping elements in the second portion <NUM>. In this way, the recombination of carriers can be suppressed and the short-circuit current and open-circuit voltage of the solar cell can be improved. It is can be seen that the doping concentration at the top surface of the first portion <NUM> is relatively close to the doping concentration at the top surface of the second portion <NUM>. In some embodiments, the doping concentration at the top surface of the first portion <NUM> may be equal to the doping concentration at the top surface of the second portion <NUM>. Thus, the doping concentration at the top surface of the first portion <NUM> is reduced, and the sheet resistance of the first portion <NUM> is much less than that of the second portion <NUM>. In this way, both a relatively low sheet resistance of the first portion <NUM> and a relatively low doping concentration of the first portion <NUM> can be achieved, thereby improving the ohmic contact of the P-type emitter <NUM> and maintaining a good passivation effect of the P-type emitter <NUM>.

In some embodiments, in a direction from the top surface of the P-type emitter <NUM> to the bottom surface of the P-type emitter <NUM>, the doping concentration in the interior of the first portion <NUM> of the P-type emitter <NUM> gradually decreases, and the doping concentration in the interior of the second portion <NUM> of the P-type emitter <NUM> gradually decreases. That is to say, each of the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM> has a descending doping concentration gradient, which is conducive to the transport of carriers in the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM> from a region with a relatively high concentration to a region with a relatively low concentration, until into the N-type substrate <NUM>. In this way, the transport speed of carriers can be increased and the open-circuit voltage of the solar cell can be improved.

In some embodiments, the difference between the doping concentration at the top surface of the first portion <NUM> and the doping concentration at the bottom surface of the first portion <NUM> is 8E<NUM> atoms/cm<NUM> to 1E<NUM> atoms/cm<NUM>. Within this range, on one hand, the difference in doping concentration in the interior of the first portion <NUM> of the P-type emitter <NUM> is relatively high, thereby facilitating the transport of carriers. On the other hand, it can be prevented that the difference in doping concentration in the interior of the first portion <NUM> of the P-type emitter <NUM> is too small, thereby preventing an excessive overall doping concentration of the first portion <NUM> due to the small difference between the doping concentration at the top surface and the doping concentration in the first portion <NUM>.

In some embodiments, the difference between the doping concentration at the top surface of the second portion <NUM> and the doping concentration at the bottom surface of the second portion <NUM> is 5E<NUM> atoms/cm<NUM> to 1E<NUM> atoms/cm<NUM>. Within this range, the doping concentration in the interior of the second portion <NUM> of the P-type emitter <NUM> will not be too low, so that the normal transport of carriers in the second portion <NUM> of the P-type emitter <NUM> can be ensured. In addition, within this range, the overall doping concentration of the second portion <NUM> of the P-type emitter <NUM> can be kept low, thus Auger recombination can be prevented from occurring in the second portion <NUM> of the P-type emitter <NUM>.

In some embodiments, at least a part of at least one inclined surface of the first pyramid structure <NUM> is concave or convex relative to a center of the first pyramid structure <NUM>, that is to say, at least one inclined surface of the first pyramid structure <NUM> has irregular deformation. This irregular deformation leads to dislocations and dangling bonds in the first portion <NUM> of the P-type emitter <NUM>, thereby forming a deep energy level in interior of the first portion <NUM> of the P-type emitter <NUM>, thus further reducing the sheet resistance of the first portion <NUM> of the P-type emitter <NUM>.

In some embodiments, the ratio of a width of the second portion <NUM> to a width of the first portion <NUM> is greater than <NUM>. That is to say, the second portion <NUM> of the P-type emitter <NUM> with relatively higher sheet resistance accounts for a higher proportion, since the second portion <NUM> of the P-type emitter <NUM> has better passivation performance and can suppress the recombination of carriers, the overall passivation performance of the P-type emitter <NUM> is good. Furthermore, since the first portion <NUM> of the P-type emitter <NUM> only needs to be electrically connected to the metal electrode to improve the ohmic contact with the metal electrode, the width of the first portion <NUM> of the P-type emitter <NUM> can be set to be small, so as to improve the ohmic contact and maintain relatively good passivation performance of the emitter.

The solar cell further includes a first metal electrode <NUM>, the first metal electrode <NUM> is formed on the first surface of the N-type substrate <NUM> and is electrically connected to the first portion <NUM> of the P-type emitter <NUM>. Since the carriers in the P-type emitter <NUM> will transport to the first metal electrode <NUM> electrically connected to the first portion <NUM> of the P-type emitter <NUM>, and the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> is relatively low, so that the contact resistance between the first portion <NUM> of the P-type emitter <NUM> and the first metal electrode <NUM> is low. In some embodiments, the metal recombination current in the first portion <NUM> of the P-type emitter <NUM> can be as high as <NUM> fA/cm<NUM>, thereby increasing the transport rate of carriers in the P-type emitter <NUM> to the first metal electrode <NUM>. In addition, since the first portion <NUM> of the P-type emitter <NUM> has a relatively deep junction depth, the conductive paste does not easily penetrate the first portion <NUM> of the P-type emitter <NUM> during the preparation of the first metal electrode <NUM>. In this way, damage to the structure of the p-n junction can be avoided, which is conducive to maintenance of the good photoelectric conversion performance of the solar cell.

In some embodiments, a width of the first metal electrode <NUM> is less than or equal to the width of the first portion <NUM> of the P-type emitter <NUM>, so that the first metal electrode <NUM> can be encapsulated by the first portion <NUM> of the P-type emitter <NUM>, i.e. the side surfaces and the bottom surface of the first metal electrode <NUM> are in contact with the first portion <NUM> of the P-type emitter <NUM>. Since the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> is relatively lower, the contact resistance between the first metal electrode <NUM> and the P-type emitter <NUM> can be further improved by designing the first metal electrode <NUM> to be encapsulated by the first portion <NUM> of the P-type emitter <NUM>, thereby improving the collection efficiency of carriers by the first metal electrode <NUM>.

In some embodiments, the solar cell further includes an anti-reflection layer <NUM> located on the top surface of the P-type emitter <NUM>, and the first metal electrode <NUM> penetrates the anti-reflection layer <NUM> to electrically connect to the P-type emitter <NUM>. The anti-reflection layer <NUM> is used for reducing reflection of incident light by the substrate. In some embodiments, the anti-reflection layer <NUM> may be a single-layer structure or a multi-layer structure, and the material of the anti-reflection layer <NUM> may be at least one of magnesium fluoride, silicon oxide, aluminum oxide, silicon oxynitride, silicon nitride, and titanium oxide.

The tunnel layer <NUM> is used to achieve interface passivation of the second surface of the substrate. In some embodiments, the material of the tunnel layer <NUM> may be a dielectric material, such as any one of silicon oxide, magnesium fluoride, silicon oxide, amorphous silicon, polycrystalline silicon, silicon carbide, silicon nitride, silicon oxynitride, aluminum oxide and titanium oxide.

The doped conductive layer <NUM> is used to form field passivation. In some embodiments, the material of the doped conductive layer <NUM> may be doped silicon. In some embodiments, the doped conductive layer <NUM> and the substrate include doping elements of the same conductivity type. The doped silicon may include one or more of N-type doped polysilicon, N-type doped microcrystalline silicon and N-type doped amorphous silicon and silicon carbide.

In some embodiments, the solar cell further includes a first passivation layer <NUM> located on a surface of the doped conductive layer <NUM> away from the substrate. In some embodiments, the material of the first passivation layer <NUM> may be one or more of magnesium fluoride, silicon oxide, aluminum oxide, silicon oxynitride, silicon nitride and titanium oxide. In some embodiments, the first passivation layer <NUM> may be a single-layer structure. In some other embodiments, the first passivation layer <NUM> may be a multi-layer structure.

In some embodiments, the solar cell further includes a second metal electrode <NUM> penetrating the first passivation layer <NUM> to form an electrical connection with the doped conductive layer <NUM>.

In the solar cell as described in the above embodiments, a P-type emitter <NUM> is formed on a first surface of an N-type substrate <NUM>, first pyramid structures <NUM> are formed on a first portion <NUM> of the P-type emitter <NUM>, a transition surface <NUM> is respectively formed on at least one edge of each first pyramid structure <NUM>, the transition surface <NUM> is joined with two adjacent inclined surfaces of the each first pyramid structure <NUM>, and the transition surface <NUM> is concave or convex relative to a center of the each first pyramid structure <NUM>, a substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, in other words, each of at least a part of the first pyramid structures <NUM> has a micro-defect. Such micro-defect can form a certain crystal change, thereby forming a defect energy level, so that the doping concentration of the first portion <NUM> of the P-type emitter <NUM> can be kept low while the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> can be greatly reduced. In this way, the generation of Auger recombination can be reduced, and the photoelectric conversion performance of the solar cell can be improved. Moreover, edges of each second pyramid structure <NUM> of the second portion <NUM> of the P-type emitter <NUM> are linear, in other words, a second pyramid structure is a normal pyramid structure. In this way, the sheet resistance of the second portion <NUM> of the P-type emitter <NUM> can be relatively high, thereby reducing the generation of recombination centers and improving the open-circuit voltage and short-circuit current of the solar cell.

Embodiments of the present disclosure further provide a photovoltaic module, referring to <FIG>, the photovoltaic module includes: a cell string formed by connecting a plurality of solar cells <NUM> as provided in the above embodiments; an encapsulation layer <NUM> used for covering a surface of the cell string; and a cover plate <NUM> used for covering a surface of the encapsulation layer <NUM> facing away from the cell string. The solar cells <NUM> are electrically connected in a form of a single piece or multiple pieces to form a plurality of cell strings, and the plurality of cell strings are electrically connected in series and/or parallel.

In some embodiments, the plurality of cell strings may be electrically connected by conductive strips <NUM>. The encapsulation layer <NUM> covers the front and back surfaces of the solar cell <NUM>. As an example, the encapsulation layer <NUM> may be an organic encapsulation adhesive film, such as an adhesive film of ethylene-vinyl acetate copolymer (EVA), an adhesive film of polyethylene octene co-elastomer (POE) or an adhesive film of polyethylene terephthalate (PET) and the like. In some embodiments, the cover plate <NUM> may be a cover plate <NUM> with a light-transmitting function, such as a glass cover plate, a plastic cover plate, or the like. As an example, the surface of the cover plate <NUM> facing the encapsulation layer <NUM> may be a concave-convex surface, thereby increasing the utilization rate of incident light.

Another embodiment of the present disclosure further provides a production method for a solar cell, the solar cell as provided in the above embodiments can be obtained by implementing the method. The production method provided by this embodiment of the present disclosure will be described in detail below with reference to the accompanying drawings.

<FIG> are structural schematic diagrams corresponding to the operations of the production method for the solar cell provided by this embodiment of the present disclosure.

The N-type substrate <NUM> is used to receive incident light and generate photogenerated carriers. In some embodiments, the N-type substrate <NUM> may be an N-type silicon substrate, and the material of the N-type silicon substrate may include at least one of monocrystalline silicon, polycrystalline silicon, amorphous silicon or microcrystalline silicon. The N-type substrate <NUM> is an N-type semiconductor substrate, that is, the N-type substrate <NUM> is doped with N-type dopant ions, and the N-type dopant ions may be any one of phosphorus ions, arsenic ions, or antimony ions.

Referring to <FIG>, a P-type emitter <NUM> is formed on a first surface of the N-type substrate <NUM>, the P-type emitter <NUM> includes a first portion <NUM> and a second portion <NUM>, first pyramid structures <NUM> are formed on a top surface of the first portion <NUM>, a transition surface <NUM> is respectively formed on at least one edge of each first pyramid structure <NUM>, the transition surface <NUM> is joined with two adjacent inclined surfaces of the each first pyramid structure <NUM>, and the transition surface <NUM> is concave or convex relative to a center of the each first pyramid structure <NUM>. A substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, and a shape of the substructure <NUM> is spherical or spherical-like. Second pyramid structures <NUM> are formed on a top surface of the second portion <NUM>, edges of each second pyramid structure <NUM> are linear. A sheet resistance of the first portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, a doping concentration at the top surface of the first portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>, a sheet resistance of the second portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the second portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>.

A transition surface <NUM> is respectively formed on at least one edge of each formed first pyramid structure <NUM>, i.e. the at least one edge of each first pyramid structure <NUM> has irregular deformation, and a spherical or spherical-like substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, so that the first pyramid structures <NUM> have micro-defects, and changes in silicon crystals are formed in the first portion <NUM> of the P-type emitter. Furthermore, edges of each second pyramid structure <NUM> are linear, in other words, there is no deformation in the edges of each second pyramid structure <NUM>. Due to the deformation in the at least one edge of each first pyramid structure <NUM> and the deformation in each of top surfaces of at least a part of the first pyramid structures <NUM>, a sheet resistance of the first portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the first portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>. Since there is no deformation in the edges of each second pyramid structure <NUM>, a sheet resistance of the second portion <NUM> ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the second portion <NUM> ranges from 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>. It is obvious that the sheet resistance of the first portion <NUM> is much less than the sheet resistance of the second portion <NUM>, but the doping concentration at the top surface of the first portion <NUM> is not much different from the doping concentration at the top surface of the second portion <NUM>. It can be seen that due to the micro-defects of the first pyramid structures <NUM>, the sheet resistance of the first portion <NUM> is much less than the sheet resistance of the second portion <NUM>, thereby greatly improving ohmic contact of the first portion <NUM> of the P-type emitter <NUM>. Meanwhile, the doping concentration of the first portion <NUM> of the P-type emitter <NUM> is kept low, so that the generations of recombination centers in the first portion <NUM> of the P-type emitter <NUM> can be reduced, the good passivation effect of the P-type emitter <NUM> can be maintained, and the generations of Auger recombination can be reduced. In this way, the photoelectric conversion performance of the solar cell can be improved.

In some embodiments, a method for forming the P-type emitter <NUM> includes the following operations.

Referring to <FIG>, an N-type initial substrate <NUM> is provided, and the N-type initial substrate <NUM> is used as a basis for forming the N-type substrate <NUM> and the P-type emitter <NUM>. Therefore, the materials of the N-type initial substrate <NUM> and the N-type substrate <NUM> may be of the same.

In some embodiments, a first surface of the N-type initial substrate <NUM> may be designed as a pyramid textured surface, so that the reflectivity of a first surface of the N-type initial substrate <NUM> to incident light is low, and the absorption and utilization rate of light is high. In some embodiments, the N-type initial substrate <NUM> is an N-type initial semiconductor substrate, that is, the N-type initial substrate <NUM> is doped with N-type dopant ions, and the N-type dopant ions may be any one of phosphorus ions, arsenic ions, or antimony ions.

The method for forming the P-type emitter <NUM> further includes, referring to <FIG>, depositing a trivalent doping source on a top surface of the N-type initial substrate <NUM>. The trivalent doping source includes a trivalent element. The trivalent doping source located on the top surface of the N-type initial substrate <NUM> is used to be subsequently diffused into the N-type initial substrate <NUM> to form the P-type emitter <NUM>. The trivalent doping source is designed to include a trivalent element, i.e. the N-type initial substrate <NUM> is doped with a single element, so that the formed P-type emitter <NUM> includes an element of a single type, and therefore becomes a high-efficiency doping layer. It is designed that there is no impurity element in the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM>, or an amount of the impurity element is very small. In this way, the problem that recombination of carriers occurs due to the impurity element becoming a recombination center can be avoided. In some embodiments, the trivalent doping source may be a boron source, and may for example be boron trichloride or boron tribromide.

Referring to <FIG>, in some embodiments, depositing the trivalent doping source on the top surface of the N-type initial substrate <NUM> includes forming a first thin film layer <NUM>. The first thin film layer <NUM> includes the trivalent dopant source and at least one of boron element, oxygen element, silicon element or chlorine element. A deposition time ranges from <NUM> to <NUM>, and a temperature ranges from <NUM> to <NUM>. In some embodiments, when the trivalent doping source is a boron source, the main components of the first thin film layer <NUM> may include silicon oxide and boron oxide, and the trivalent doping source may be stored in the first thin film layer <NUM> in a form of boron oxide. Since silicon oxide has high hardness, it can protect the N-type initial substrate <NUM> during the doping process.

In addition, since the thickness of the first thin film layer <NUM> is relatively small, when a relatively thin first thin film layer <NUM> includes relatively many trivalent doping sources, the trivalent doping sources aggregates in the first thin film layer <NUM>, thereby increasing the concentration of the trivalent doping source. In this way, when the trivalent doping source is subsequently diffused into the N-type initial substrate <NUM> by the doping process, the doping process is facilitated and it is easier to form the first portion <NUM> of the P-type emitter <NUM> with relatively high doping concentration, thereby reducing the sheet resistance of the first portion <NUM> of the P-type emitter <NUM>. In addition, since the thickness of the first thin film layer <NUM> is relatively small, the trivalent doping source that can be included in the first thin film layer <NUM> will not be too much, so that excessive trivalent doping source elements can prevented from being doped into the N-type initial substrate <NUM>. In this way, the problem that relatively many trivalent doping source elements become strong recombination centers due to too many trivalent doping source elements being contained in the N-type initial substrate <NUM>, which leads to poor passivation capability of the formed first portion <NUM> of the P-type emitter <NUM> can be prevented.

In some embodiments, a method for forming the first thin film layer <NUM> may include depositing a trivalent doping source on the first surface of the N-type initial substrate <NUM>. In some embodiments, boron trichloride may be deposited, as the trivalent doping source, on the first surface of the N-type initial substrate <NUM> by chemical vapor deposition or spin coating.

As an example, the method for forming the first thin film layer <NUM> may include: performing a boat feeding process on the N-type initial substrate <NUM>; after the boat feeding process of the N-type initial substrate <NUM>, raising a temperature to a first preset temperature, and depositing a trivalent doping source on the first surface of the N-type initial substrate <NUM>, the first preset temperature may be <NUM> to <NUM>; then raising the temperature to a second preset temperature, the second preset temperature is greater than the first preset temperature, for example, the second preset temperature may be <NUM> to <NUM>; and performing a junction pushing process in a nitrogen atmosphere, which can improve the density and uniformity of the formed first thin film layer <NUM>. In some embodiments, while depositing the trivalent doping source, a small amount of oxygen may be introduced, for example, <NUM> sccm to <NUM> sccm, which is conducive to the further formation of a first thin film layer <NUM> with relatively high density.

Referring to <FIG>, after depositing the trivalent dopant source, a preset region of the top surface of the N-type initial substrate <NUM> is treated using a process of external energy source treatment, and the trivalent dopant source treated by the process of external energy source treatment is diffused into an interior of the N-type initial substrate <NUM> to form the first portion <NUM> of the P-type emitter <NUM> in the preset region of the N-type initial substrate <NUM>, and a top surface of the first portion <NUM> of the P-type emitter <NUM> is exposed from the N-type initial substrate <NUM>. The process of external energy source treatment is performed on the preset region, so that the trivalent doping source in the preset region of the first thin film layer <NUM> is diffused into the interior of the N-type initial substrate <NUM>. At the same time, with the process of external energy source treatment, the structure of the preset region at the top surface of the N-type initial substrate <NUM> is changed to form the first pyramid structures <NUM>. It is noted that the structure of the N-type initial substrate <NUM> is a regular tetrahedral structure before performing the process of external energy source treatment. After the process of external energy source treatment, at least one edge of each first pyramid structure <NUM> deforms to form a transition surface <NUM>, and a substructure is formed on each of top surfaces of at least a part of the first pyramid structures. After the preset region of the N-type initial substrate <NUM> is doped with the trivalent doping source, the top surface of the formed first portion <NUM> of the P-type emitter <NUM> has the first pyramid structures <NUM>. In this way, a deep energy level can be formed in the first portion <NUM> of the P-type emitter <NUM>, thus the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> can be reduced.

In some embodiments, the process of external energy source treatment includes a laser doping process. In the laser doping process, a wavelength of the laser ranges from <NUM> to <NUM>, for example, <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>. By controlling a focal position and laser wavelength of the laser parameters, structural morphologies at different positions of the first pyramid structures <NUM> can be changed. In addition, due to the simple operation of the laser process, the laser parameters are easy to control, so that the morphologies of the formed first pyramid structures <NUM> is as expected. By setting the wavelength and energy density of the laser within this range, deformation occurs on at least one edge of each first pyramid structure <NUM>, and a spherical or spherical-like substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>. Due to the micro-defects of the formed first pyramid structures <NUM>, crystal changes are formed in the first portion <NUM> of the P-type emitter <NUM>, thereby forming a defect energy level, so that the doping concentration of the first portion <NUM> of the P-type emitter <NUM> can be kept low while the sheet resistance of the first portion <NUM> can be greatly reduced. In this way, not only the ohmic contact can be greatly improved, but also a good passivation effect of the first portion <NUM> of the P-type emitter <NUM> can be maintained, and the short-circuit voltage and open-circuit current of the solar cell can be improved.

In another embodiment, the process of external energy source treatment may also include plasma irradiation or a directional ion implantation process.

In some embodiments, after forming the first portion <NUM> of the P-type emitter <NUM>, the method further includes: performing a cleaning operation on the first surface of the N-type initial substrate <NUM> to remove the first thin film layer <NUM>. In this way, the remaining trivalent doping sources in the first thin film layer <NUM> and the adsorbed impurities on the surface of the N-type initial substrate <NUM> can be removed, which is conducive to prevention of leakage. Furthermore, the first thin film layer <NUM> contains a large number of trivalent doping sources, and these trivalent doping sources will be converted into non-activated trivalent doping sources, such as non-activated boron, in the subsequent high temperature process for forming the second thin film layer. The existence of the non-activated trivalent doping sources will increase the recombination of carriers on the surface of the N-type initial substrate <NUM>, thereby affecting the photoelectric conversion efficiency of the solar cell. Therefore, removing the first thin film layer <NUM> before the operation of forming the second thin film layer can also reduce the content of the non-activated trivalent doping sources on the surface of the N-type initial substrate <NUM> after subsequently forming the second thin film layer, thereby reducing the recombination of carriers on the surface of the N-type initial substrate <NUM> and improving the photoelectric conversion efficiency of the solar cell. As an example, the cleaning operation may include cleaning the surface of the N-type initial substrate <NUM> with alkali solution or acid solution, where the alkali solution may be at least one of KOH or H<NUM>O<NUM> aqueous solution, and the acid solution may be at least one of HF or HCl aqueous solution.

After forming the first portion <NUM> of the P-type emitter <NUM>, referring to <FIG>, a high temperature treatment is performed on the N-type initial substrate <NUM> to form the P-type emitter <NUM> in the N-type initial substrate <NUM>, and the top surface of the P-type emitter <NUM> is exposed from the N-type initial substrate <NUM>. As an example, the N-type substrate <NUM> is formed in a region of the N-type initial substrate <NUM> excluding the P-type emitter <NUM>, and the second portion <NUM> of the P-type emitter <NUM> is formed in a region of the P-type emitter <NUM> excluding the preset region. Since the process of external energy source treatment is only performed on the surface of the preset region of the N-type initial substrate <NUM>, the trivalent doping sources in the first thin film layer <NUM> corresponding to the preset region are diffused into the interior of the N-type initial substrate <NUM>. Thus, the junction depth of the formed first portion <NUM> of the P-type emitter <NUM> is greater than the junction depth of the second portion <NUM> of the P-type emitter <NUM>. Thus, the metal electrode can be arranged to be in electrical connection with the first portion <NUM> of the P-type emitter <NUM>. In this way, the problem that the paste for forming the metal electrode penetrates the P-type emitter <NUM> and directly contacts with the N-type initial substrate <NUM> during the sintering process can be prevented. Moreover, the junction depth of the second portion <NUM> is designed to be shallow, that is, the thickness of the second portion <NUM> of the P-type emitter <NUM> is small, so that the number of doping elements in the second portion <NUM> is less than the number of doping elements in the first portion <NUM>, that is, the doping concentration of the second portion <NUM> of the P-type emitter <NUM> is lower. Therefore, compared with the first portion <NUM> of the P-type emitter <NUM>, the second portion <NUM> of the P-type emitter <NUM> has a better passivation effect, which is conducive to reduction of the recombination of carriers and to improvement of the open-circuit voltage and short-circuit current of the solar cell.

After performing the high temperature treatment on the N-type initial substrate <NUM>, part of the trivalent doping sources is doped into the N-type initial substrate <NUM>, so that part of the N-type initial substrate <NUM> is transformed into the second portion <NUM> of the P-type emitter <NUM>. That is to say, the portion of the N-type initial substrate <NUM> excluding the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM> corresponds to the N-type substrate <NUM>.

Referring to <FIG>, in some embodiments, in the operation of performing the high temperature treatment on the N-type initial substrate <NUM>, oxygen of a flow rate of 500sccm to 50000sccm is introduced for a duration ranged from Smins to 300mins and under a temperature ranged from <NUM> to <NUM>, to form a second thin film layer <NUM>. A thickness of the second thin film layer <NUM> is smaller than a thickness of the first thin film layer <NUM>. The amount of the oxygen introduced in the process of forming the second thin film layer <NUM> is relatively large, so that the oxygen can react with more trivalent doping sources, thus the thickness of the formed second thin film layer <NUM> is larger than the thickness of the first thin film layer <NUM>. In this way, on one hand, when the thinner first thin film layer <NUM> includes more trivalent doping sources, the trivalent doping sources aggregate in the first thin film layer <NUM>, thereby increasing the concentration of the trivalent doping sources, which is conducive to the laser doping, and because the first thin film layer <NUM> is relatively thin, it is easy for the laser to penetrate into the N-type initial substrate <NUM>. On the other hand, the second thin film layer <NUM> is thicker, which can ensure that the amount of trivalent doping sources absorbed by the second thin film layer <NUM> in a region excluding the preset region of the first surface of the N-type initial substrate <NUM> is relatively large. In this way, the doping concentration at the top surface of the first portion <NUM> of the P-type emitter <NUM> and the doping concentration at the top surface of the second portion <NUM> of the P-type emitter <NUM> can be reduced, and the passivation performance can be improved.

Referring to <FIG>, in some embodiments, the method further includes: performing the cleaning operation on the N-type initial substrate <NUM> to remove the second thin film layer <NUM>; forming an anti-reflection layer <NUM> on the first surface of the N-type initial substrate <NUM>, and the anti-reflection layer <NUM> is located on the top surface of the P-type emitter <NUM>. In some embodiments, the anti-reflection layer <NUM> may be a single-layer structure or a multi-layer structure, and the material of the anti-reflection layer <NUM> may be at least one of magnesium fluoride, silicon oxide, aluminum oxide, silicon oxynitride, silicon nitride or titanium oxide. In some embodiments, the anti-reflection layer <NUM> may be formed by a plasma enhanced chemical vapor deposition (PECVD) method.

Referring to <FIG>, the method further includes: forming a first metal electrode <NUM> being electrically connected to the first portion <NUM> of the P-type emitter <NUM>. The first metal electrode <NUM> is located on the first surface of the N-type initial substrate <NUM>. Since the sheet resistance of the first portion <NUM> of the P-type emitter <NUM> is low, the first metal electrode <NUM> is arranged to be electrically connected to the first portion <NUM> of the P-type emitter <NUM>. In this way, the contact resistance between the first metal electrode <NUM> and the first portion <NUM> of the P-type emitter <NUM> can be reduced, thereby facilitating the transport of carriers in the first metal electrode <NUM> penetrating the anti-reflection layer <NUM>. This because the carriers in the first portion <NUM> of the P-type emitter <NUM> and the second portion <NUM> of the P-type emitter <NUM> will transport to and be collected by the first metal electrode <NUM> in contact with the first portion <NUM> of the P-type emitter <NUM>. That is to say, the electrons in the first portion <NUM> and the second portion <NUM> are desired to transport to the first metal electrode <NUM> in contact with the first portion <NUM> of the P-type emitter <NUM>. Therefore, the transport of carrier can be greatly improved by the improvement of the contact resistance between the first metal electrode <NUM> and the first portion <NUM> of the P-type emitter <NUM>.

In some embodiments, a method for forming the first metal electrode <NUM> includes: printing conductive paste on a top surface of the anti-reflection layer <NUM> in the preset region, the conductive material in the conductive paste may be at least one of silver, aluminum, copper, tin, gold, lead or nickel; and sintering the conductive paste, for example, the sintering may be performed under a peak temperature of <NUM> to <NUM>, so as to penetrate the anti-reflection layer <NUM> to form the first metal electrode <NUM>.

Referring to <FIG>, a tunnel layer <NUM> and a doped conductive layer <NUM> are formed over a second surface of the N-type substrate <NUM> in a direction away from the N-type substrate <NUM>.

The tunnel layer <NUM> is used to realize the interface passivation of the second surface of the N-type substrate <NUM>. In some embodiments, the tunnel layer <NUM> may be formed using a deposition process, such as a chemical vapor deposition process. In some other embodiments, the tunnel layer <NUM> may be formed using an in-situ generation process. As an example, in some embodiments, the material of the tunnel layer <NUM> may be any one of silicon oxide, magnesium fluoride, amorphous silicon, polycrystalline silicon, silicon carbide, silicon nitride, silicon oxynitride, aluminum oxide and titanium oxide.

The doped conductive layer <NUM> is used to form field passivation. In some embodiments, the material of the doped conductive layer <NUM> may be doped silicon. In some embodiments, the doped conductive layer <NUM> and the N-type substrate <NUM> include doping elements of the same conductivity type, the doped silicon may include one or more of N-type doped polysilicon, N-type doped microcrystalline silicon, N-type doped amorphous silicon and silicon carbide. In some embodiments, the doped conductive layer <NUM> may be formed using a deposition process. As an example, intrinsic polysilicon may be deposited on the surface of the tunnel layer <NUM> away from the N-type substrate <NUM> to form a polysilicon layer, and phosphorus ions may be doped in manners of ion implantation and source diffusion to form an N-type doped polysilicon layer. The N-type doped polysilicon layer serves as the doped conductive layer <NUM>.

Referring to <FIG>, in some embodiments, the method further includes forming a first passivation layer <NUM> on a surface of the doped conductive layer <NUM> away from the N-type substrate <NUM>. In some embodiments, the material of the first passivation layer <NUM> may be one or more of magnesium fluoride, silicon oxide, aluminum oxide, silicon oxynitride, silicon nitride and titanium oxide. In some embodiments, the first passivation layer <NUM> may be a single-layer structure. In some other embodiments, the first passivation layer <NUM> may be a multi-layer structure. As an example, in some embodiments, the first passivation layer <NUM> may be formed using a PECVD method.

In some embodiments, the method further includes forming a second metal electrode <NUM> penetrating the first passivation layer <NUM> to form an electrical connection with the doped conductive layer <NUM>. As an example, the method for forming the second metal electrode <NUM> may be the same as the method for forming the first metal electrode <NUM>, and the material of the first metal electrode <NUM> may be the same as the material of the second metal electrode <NUM>.

In the production method for a solar cell as provided by the above embodiments, the at least one edge of each formed first pyramid structure <NUM> has irregular deformation, and a spherical or spherical-like substructure <NUM> is formed on each of top surfaces of at least a part of the first pyramid structures <NUM>, so that the first pyramid structures <NUM> have micro-defects, and changes in silicon crystals are formed in the first portion <NUM> of the P-type emitter. Furthermore, edges of each second pyramid structure <NUM> are linear, in other words, there is no deformation in the edges of each second pyramid structure <NUM>. Due to the micro-defects of the first pyramid structures <NUM>, the sheet resistance of the first portion <NUM> is much less than the sheet resistance of the second portion <NUM>, thereby greatly improving ohmic contact of the first portion <NUM> of the P-type emitter <NUM>. Meanwhile, the doping concentration of the first portion <NUM> of the P-type emitter <NUM> is kept low, so that the generations of recombination centers in the first portion <NUM> of the P-type emitter <NUM> can be reduced, the good passivation effect of the P-type emitter <NUM> can be maintained, and the generations of Auger recombination can be reduced. In this way, the photoelectric conversion performance of the solar cell can be improved.

The comparative example provides a solar cell, including: a substrate; an emitter formed on a first surface of the substrate, the emitter includes a first portion <NUM> (refer to <FIG>) and a second portion <NUM> (refer to <FIG>), a top surface of the first portion <NUM> includes a third pyramid structure whose edges are linear, and a top surface of the second portion <NUM> includes a fourth pyramid structure whose edges are linear. A doping concentration of the first portion <NUM> is greater than a doping concentration of the second portion <NUM>, and a sheet resistance of the first portion <NUM> is lower than a sheet resistance of the second portion <NUM>.

Compared with the structure of the solar cell according to embodiments of the present disclosure as shown in <FIG>, the difference between the structure of the solar cell according to the comparative example and that according to the embodiments of the present disclosure lies in that, in the comparative example, the edges of the third pyramid structure on the top surface of the first portion are linear. Based on comparative experiment, the parameters according to the embodiments of the present disclosure and those according to the comparative example are compared as shown in Table <NUM>:.

It can be seen from Table <NUM> that, compared with the comparative example, each of the open-circuit voltage, short-circuit current density, filling factor and conversion efficiency of the solar cell according to embodiments of the present disclosure is higher, so that the solar cell according to embodiments of the present disclosure has a better conversion performance. It can be seen that, due to the micro-defects of the first pyramid structures <NUM>, the sheet resistance of the first portion <NUM> (refer to <FIG>) is greatly reduced, thereby greatly improving ohmic contact of the first portion <NUM> of the P-type emitter <NUM> (refer to <FIG>). Meanwhile, the doping concentration of the first portion <NUM> of the P-type emitter <NUM> is relatively low, so that the generations of recombination centers in the first portion <NUM> of the P-type emitter <NUM> can be reduced, a good passivation effect of the P-type emitter <NUM> can be maintained, and the generations of Auger recombination can be reduced. In this way, the photoelectric conversion performance of the solar cell can be improved.

Although the present disclosure is disclosed above with exemplary embodiments, they are not used to limit the claims. Any person skilled in the art can make some possible changes and modifications without departing from the concept of the present disclosure. The scope of protection of the present disclosure shall be subject to the scope defined by the claims.

Claim 1:
A solar cell, characterized by comprising:
an N-type substrate (<NUM>);
a P-type emitter (<NUM>) formed on a first surface of the N-type substrate (<NUM>), wherein the P-type emitter (<NUM>) comprises a first portion (<NUM>) and a second portion (<NUM>), first pyramid structures (<NUM>) are formed on a top surface of the first portion (<NUM>), and second pyramid structures (<NUM>) are formed on a top surface of the second portion (<NUM>), wherein a transition surface (<NUM>) is respectively formed on at least one edge of each first pyramid structure (<NUM>), the transition surface (<NUM>) is joined with two adjacent inclined surfaces of the each first pyramid structure (<NUM>), and the transition surface (<NUM>) is concave or convex relative to a center of the each first pyramid structure (<NUM>), wherein a substructure (<NUM>) is formed on each of top surfaces of at least a part of the first pyramid structures (<NUM>), and a shape of the substructure (<NUM>) is spherical or spherical-like, wherein edges of each second pyramid structure (<NUM>) are straight, and
wherein a sheet resistance of the first portion (<NUM>) ranges from <NUM> ohm/sq to <NUM> ohm/sq, a doping concentration at the top surface of the first portion (<NUM>) ranges from 1E<NUM>atoms/cm<NUM> to 8E<NUM>atoms/cm<NUM>, a sheet resistance of the second portion (<NUM>) ranges from <NUM> ohm/sq to <NUM> ohm/sq, and a doping concentration at the top surface of the second portion (<NUM>) ranges from 1E<NUM>atoms/cm<NUM> to 5E<NUM>atoms/cm<NUM>;
a tunnel layer (<NUM>) and a doped conductive layer (<NUM>) sequentially formed over a second surface of the N-type substrate (<NUM>) in a direction away from the N-type substrate (<NUM>); and
a first metal electrode (<NUM>) formed on the first surface of the N-type substrate (<NUM>), wherein the first metal electrode is electrically connected to the first portion of the P-type emitter.