Method for Producing a Contact Layer of a Solar Module and Solar Module Produced in This Manner

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This patent describes a novel method for manufacturing the contact layer of a solar module, in which a special gradient is created. In this gradient, both the electrical resistance and the light transmittance (transmission) increase in the same direction across the contact layer's surface. The gradient may be introduced using methods like controlled laser treatment or by varying the material properties during deposition. The resulting solar module demonstrates improved efficiency by locally optimizing the contact layer for both electrical conductivity and optical transmission according to the local current density.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of higher-efficiency thin-film solar modules for residential rooftops or commercial installations.
• Manufacture of large-area solar panels for solar farms and utility-scale power generation.
• Integration of gradient contact layers into various types of photovoltaic devices (amorphous, microcrystalline, or tandem solar cells).
• Development of advanced building-integrated photovoltaics (BIPV) where maximizing efficiency on non-uniform surfaces is critical.
• Adaptation in flexible or substrate-specific solar panels (e.g., glass, flexible foil, metal) for a range of portable or custom applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Increases solar module efficiency by reducing both optical and electrical losses through gradient-tuned contact layers.
• Allows for local optimization of conductivity and transparency, matching the actual current density distribution across the cell.
• Compatible with existing manufacturing techniques, such as sputtering and laser processing, enabling relatively easy adoption in current factories.
• Can be applied to a wide range of substrate materials and solar cell architectures, enhancing manufacturing flexibility.
• Potentially reduces material costs or enables material savings by more strategically allocating conducting and transparent material properties.
• The patent reports measured efficiency gains (e.g., up to 7% increase over non-gradient designs), offering significant competitive advantage.

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Patent Abstract

The invention relates to a method for producing a contact layer of a solar module, the material of the contact layer being arranged on a substrate in order to form a surface. The method is characterized in that a gradient is formed in the contact layer and the electrical resistance and the transmittance increase along the gradient in the same direction as that of the surface. The invention further relates to a solar module produced in such manner.