METHOD FOR PREVENTING AN ELECTRICAL SHORTAGE IN A SEMICONDUCTOR LAYER STACK, THIN SUBSTRATE CPV CELL, AND SOLAR CELL ASSEMBLY
20170170357 ยท 2017-06-15
Inventors
Cpc classification
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H10F77/63
ELECTRICITY
H10F77/60
ELECTRICITY
International classification
H01L31/18
ELECTRICITY
H01L31/052
ELECTRICITY
Abstract
The invention relates to a method for preventing an electrical shortage between at least two layers of a semiconductor layer stack attached by the surface of one of its layers to a substrate via a conductive adhesive by providing an isolating layer on the side walls of the stack or by removing excess material after attaching the stack to the substrate. The invention also relates to a thin substrate CPV cell and to a solar cell assembly.
Claims
1. A method for preventing an electrical shortage between at least two layers of a semiconductor layer stack attached by a surface of one layer of the at least two layers to a substrate via a conductive adhesive, the method comprising: providing a semiconductor layer stack comprising two main surfaces corresponding to free surfaces of outermost layers of the semiconductor layer stack, and at least one side wall connecting the two main surfaces; attaching a substrate to the semiconductor layer stack via a conductive adhesive provided between one of the two main surfaces of the semiconductor layer stack and the substrate; and at least partially removing excess material of the conductive adhesive from the at least one side wall adjacent to the one of the main surfaces of the semiconductor layer stack attached to the substrate.
2. The method of claim 1, wherein at least partially removing the excess material of the conductive adhesive comprises using a thermal treatment to at least partially remove the excess material of the conductive adhesive.
3. The method of claim 2, wherein using the thermal treatment to at least partially remove the excess material of the conductive adhesive comprises using a laser ablation technique to at least partially remove the excess material of the conductive adhesive.
4. A method for preventing an electrical shortage between at least two layers of a semiconductor layer stack attached by a surface of one layer of the at least two layers to a substrate via a conductive adhesive, the method comprising: providing a semiconductor layer stack comprising two main surfaces corresponding to free surfaces of outermost layers of the semiconductor layer stack, and at least one side wall connecting the two main surfaces; providing an isolating layer on at least a portion of the at least one side wall of the semiconductor layer stack; and attaching a substrate to the semiconductor layer stack via a conductive adhesive provided between one of the two main surfaces of the semiconductor layer stack and the substrate.
5. The method of claim 4, wherein providing the isolating layer on at least a portion of the at least one side wall of the semiconductor layer stack comprises providing the isolating layer on a portion of the at least one side wall adjacent the one of the two main surfaces of the semiconductor layer stack attached to the substrate.
6. The method of claim 4, further comprising forming the isolating layer to cover a plurality of layers in the semiconductor layer adjacent the one of the two main surfaces of the semiconductor layer stack attached to the substrate.
7. The method of claim 4, wherein providing the isolating layer comprises depositing the isolating layer by thermal spraying.
8. The method of claim 7, wherein depositing the isolating layer by thermal spraying comprising depositing the isolating layer by plasma spraying.
9. The method of claim 4, wherein the semiconductor layer stack comprises a photovoltaic cell.
10. The method of claim 9, wherein the photovoltaic cell comprises a thin substrate concentrated photovoltaic (CPV) cell.
11. The method of claim 10, wherein the substrate comprises a heat sink and the conductive adhesive comprises a thermal contact paste.
12. The method of claim 11, wherein the thermal contact paste comprises a silver paste.
13. The method of claim 4, wherein providing the isolating layer further comprises: applying an etch mask to the one of the two main surfaces of the semiconductor layer stack to be attached to the substrate; at least partially etching into an unmasked area of the one of the two main surfaces of the semiconductor layer stack to be attached to the substrate, and forming at least one etched hole; at least partially covering at least one side wall of the at least one etched hole with a passivation material; and at least partially filling the at least one etched hole with an isolating material after at least partially covering the at least one side wall of the at least one etched hole with the passivation material.
14. The method of claim 13, further comprising cutting through the at least partially filled at least one etched hole to obtain the at least one semiconductor layer stack having two main surfaces corresponding to free surfaces of outermost layers of the at least one semiconductor layer stack, and at least one side wall connecting the two main surfaces, wherein the isolating layer covers at least a portion of the at least one side wall adjacent the one of the two main surfaces of the semiconductor layer stack to be attached to the substrate.
15. A solar cell assembly, comprising: a semiconductor layer stack comprising at least a portion of a thin substrate concentrated photovoltaic (CPV) cell, the semiconductor layer stack attached to a heat sink by a thermal contact paste; wherein the thin substrate CPV cell comprises two main surfaces corresponding to free surfaces of outermost layers of the semiconductor layer stack, and at least one side wall connecting the two main surfaces; wherein the heat sink comprises at least one free surface; and wherein the thermal contact paste is provided only between one of the two main surfaces of the semiconductor layer stack and the at least one free surface of the heat sink.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will be described in more detail in the following, based on advantageous embodiments described in conjugation with the following figures:
[0034]
[0035]
[0036]
DETAILED DESCRIPTION
[0037] A first embodiment of the inventive method for preventing an electrical shortage between at least two layers of a semiconductor layer stack attached by the surface of one of its layers to a substrate via a conductive adhesive is illustrated in steps A to G of
[0038] According to this embodiment of the inventive method, steps A and B of
[0039] In the first embodiment, the semiconductor layer stack 101 can be a thin substrate concentrated photovoltaic (CPV) cell 101, the substrate 109 can be a heat sink 109, and the conductive adhesive 110 can be a silver thermal contact paste 110.
[0040] The first embodiment of the inventive method will be described in more detail in the following paragraphs.
[0041] Step A of
[0042] As illustrated in step B of
[0043] In the first embodiment, an isolating layer 109 is at least partially provided on at least one side wall 104 of the layer stack 101 toward the main surface 101b of the layer stack 101 that will be attached to the heat sink 109. The isolating layer 108 can be provided over all layers or, as illustrated in step C, over only some layers or even only one layer toward the lower main surface 101b.
[0044] In this embodiment, the isolating layer 108 is deposited by thermal spraying, in particular, by plasma spraying, as shown in steps C and D of
[0045] In step C of
[0046] In step D of
[0047] In the first embodiment, the rotating table 102 allows for depositing the isolating layer 108 all around the layer stack 101. Depending on the adjustment of the laser, the deposited isolating layer 108 will be present on one or more layers toward the lower edges 104 of the layer stack 101, toward the main surface 101b, or even over the entire side walls of the layer stack 101.
[0048] In steps E to G of
[0049] In step E of
[0050] Step G of
[0051] Thus, during the attachment of the layer stack 101 to the substrate 109, the excess material of the conductive adhesive 110 that overflows from under layer stack 101 so that it at least partially covers the side walls of the layer stack 101 as illustrated in step G of
[0052] A second embodiment of the inventive method for preventing an electrical shortage between at least two layers of a semiconductor layer stack attached by the surface of one of its layers to a substrate via a conductive adhesive is illustrated in steps A to F of
[0053] According to this embodiment, steps A to D of
[0054] In the second embodiment, the semiconductor layer stack 201 can correspond to a thin substrate concentrated photovoltaic (CPV) cell 201, the substrate 202 can be a heat sink, and the conductive adhesive 203 can be silver thermal contact paste.
[0055] The second embodiment of the inventive method will be described in more details in the following paragraphs.
[0056] Step A of
[0057] In step B of
[0058] In step D of
[0059] During the assembly process of the second embodiment, a surplus of the conductive adhesive 203 used for the attachment of the layer stack 201 to the substrate 202 spills over the edges of the layer stack 201 so that it at least partially covers at least two of its layers on at least one of its side walls 201c, as illustrated in step D of
[0060] According to the second embodiment, a shortage between the at least two layers of the layer stack 201 that are brought in contact by the surplus of conductive adhesive 203 can be prevented by removing the excess material of the conductive adhesive 203 using a thermal treatment, in particular, by laser ablation. This is illustrated in step E of
[0061] Laser ablation has the advantage that the surplus of adhesive material 203 can be removed with high precision, while keeping the assembled structure intact. Optimal results can be obtained by adjusting the laser wavelength and power to the adhesive paste 203 material in order to perform the removal as selectively as possible. For removal of the excess material from all sides of the layer stack 101, the stack can again be positioned on a rotation table, like in the first embodiment.
[0062] Step F of
[0063] The first and second embodiments can furthermore be combined. Thus, a deposition of an isolating layer 108 can be accompanied by a laser ablation step.
[0064] In
[0065] In the third embodiment, the semiconductor layer stack is a thin substrate concentrated photovoltaic (CPV) cell wafer 301 from which a plurality of individual thin substrate CPV cells 309a, 309b, 309c, 309d are obtained in subsequent steps of the embodiment. The substrate can be a heat sink 310a, 310b, 310c, 310d, and the conductive adhesive 311a, 311b, 311c, 311d can be a silver thermal contact paste. The third embodiment of the inventive method will be described in more detail in the following paragraphs.
[0066] The third embodiment comprises the steps of: providing a semiconductor layer stack as illustrated in step A of
[0067] These steps will be described more in detail in the following paragraphs.
[0068] In the third embodiment, the semiconductor layer stack 301 is a thin substrate CPV cell wafer 301 out of which individual thin substrate CPV cells 309a, 309b, 309c, 309d can be produced. The third embodiment of the inventive method has the advantage that the step of isolating the lower edges of the thin substrate CPV cells can be realized during the production of the individual CPV cell from the original wafer, and thus the inventive method can be integrated in the industrial production and assembly processes of thin substrate CPV cells and SCAs.
[0069] As illustrated in step A of
[0070] The layer stack 301 illustrated in step A of
[0071] In step B, illustrated in
[0072] However, the shape and size of the etch masks 302a, 302b, 302c, 302d can be adapted to the needs of the fabrication process and/or the final product. Furthermore, the formation of the individual elements 301a to 301d on the opposite side of the layer stack 301 could also be realized after providing the mask on surface 302.
[0073] Step C of
[0074] The depth of the trenches covers a thickness at least equal or superior to the thickness of the two bottom layers of the layer stack 301 toward the masked main surface 302.
[0075] The next step of the third embodiment is illustrated in step D of
[0076] Step E of
[0077] Subsequently, as illustrated in step F of
[0078] The cutting can, e.g., be realized with a laser or any other means adapted for cutting individual CPV cells 309a, 309b, 309c, 309d from a layer stack 301.
[0079] After removal of the etch mask 302a, 302b, 302c, 302d, individual layer stacks 309a, 309b, 309c, 309d are achieved with two main surfaces corresponding to the free surfaces of the outermost layers and side walls 3031, 3032, 3033, 3034, 3035, 3036 connecting the two main surfaces, wherein the side walls 3031, 3032, 3033, 3034, 3035, 3036 are at least partially covered by an isolating layer 307b, 307c, 307d, 308a, 308b, 308c toward the main surface 302 where the attachment will occur. The isolating layer may only be formed of the passivation material 304b, 304c, 304d, 305a, 305b, 305c or, in addition as illustrated in step G, also comprise remaining filling material 307b, 307c, 307d, 308a, 308b, 308c.
[0080] Of course, the etch mask removal step may also be carried out before cutting.
[0081] Thus, the individual layer stacks 309a, 309b, 309c, 309d forming CPV cells obtained after step G comprise two main surfaces 301a, 301b, 301c, 301d, 302 corresponding to the free surfaces of their outermost layers, and side walls 3031, 3032, 3033, 3034, 3035, 3036 connecting the two main surfaces 301a, 301b, 301c, 301d, 302, which are at least partially covered by an isolating layer, here formed by the passivation material 304b, 304c, 304d, 305a, 305b, 305c and the remaining filling material 307b, 307c, 307d, 308a, 308b, 308c. In particular, the isolating layers cover the side walls 3031, 3032, 3033, 3034, 3035, 3036 toward the lower main surface 302 of the cells 309a, 309b, 309c, 309d over a plurality of layers of the layer stack 309a, 309b, 309c, 309d.
[0082] In the next step, the individual layer stacks 309a to 309d are attached to their respective substrate via a conductive adhesive. In this manner, individual CPV cells are connected to their heat sink. Step H of
[0083] The inventive SCAs 312c comprise the layer stack 309c forming the thin substrate CPV cell of the assembly. The layer stack 309c is attached to a substrate 310c forming the heat sink using a conductive adhesive 311c, here a thermal contact paste; here, a silver paste. The individual thin substrate CPV cell 309c is attached to the substrate 312c with the main surface that is adjacent the layers with the isolation layer 313.
[0084] During the attachment of the layer stack 309c to the heat sink 310c, the excess of the conductive adhesive 311c provided between the attachment surface of the substrate 310c and the attachment surface of the layer stack 309c may overflow from under the layer stack 309c so that it at least partially covers the side walls of the stack, e.g., at least the two lower layers of the layer stack 309c, as illustrated in step H of
[0085] Since the layer stack 309c comprises the isolating layers with the passivation and filling material 307b, 307c, 307d, 308a, 308b, 308c on the lower part of their side walls 3031, 3032, 3033, 3034, 3035, 3036, covering a thickness at least equal or superior to that of their respective two bottom layers, no electrical shortage can occur between the lower layers of the layer stack 309c toward the main surface 302 attached to the substrate 310c, because these layers are electrically isolated from the thermal contact paste 311c.
[0086] Thus, the embodiments and their various variants and combinations can efficiently prevent an electrical shortage between layers of a thin substrate CPV cell when the cell is attached to a heat sink by a conductive adhesive, before or after the assembly process.