Laser microspot welding for interconnection of back-contacted silicon solar cells

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Assembly cell for the manufacturing of flexible solar modules in building integrated photovoltaics

The current use of photovoltaics is often limited to the utilization of roof surfaces or ground-mounted systems. In particular, building integrated photovoltaics (BIPV) have enormous potential to make energy production more sustainable, because the energy is generated where it is used. However, most of these modules either do not meet the aesthetic requirements of the architects as well as the building owner or are uneconomical, since visually appealing building-integrated PV modules cost several times more than standard modules. In this article, an approach for a (semi) automated assembly line that allows geometry- and material-flexible manufacturing of PV modules is presented. The challenges in automating the flexible manufacturing processes include mainly the handling of limp components and the complexity of geometry variability. Appropriate gripper systems are required to ensure safe and reliable handling of the components. A gripper developed in this article offers the ability to flexibly deposit solar strings. Preliminary tests show that 66% of all conducted trials meet the accuracy requirements

Thin crystalline macroporous silicon solar cells with ion implanted emitter

We separate a (34 ± 2) μm-thick macroporous Si layer from an n-type Si wafer by means of electrochemical etching. The porosity is p = (26.2 ± 2.4)%. We use ion implantation to selectively dope the outer surfaces of the macroporous Si layer. No masking of the surface is required. The pores are open during the implantation process. We fabricate a macroporous Si solar cell with an implanted boron emitter at the front side and an implanted phosphorus region at the rear side. The short-circuit current density is 34.8 mA cm-2 and the open-circuit voltage is 562 mV. With a fill factor of 69.1% the cell achieves an energy-conversion efficiency of 13.5%.Federal Ministry for Environment, Nature Conservation, and Nuclear Safety/FKZ 032514

Laser-welded interconnection of screen-printed Si solar cells

We demonstrate the laser welding of Al interconnects to the BSF rear-side of screen-printed two-side-contacted solar cells. The Al paste on the rear side of solar cell is laser-welded to an Al foil. This reduces the silver consumption of the solar cells by making silver pads on the rear side obsolete. Our proof-of-concept modules are free of laser damage. A 3-cell-module from 6" solar cells shows no change in fill factor within the statistical measurement uncertainty after artificial aging in 500 humidityfreeze cycles.German Ministry for the Environment, Nature Conservation, and Reactor Safety/0325192State of Lower Saxon

Simultaneous Contacting and Interconnection of Passivated Emitter and Rear Solar Cells

The back end process of passivated emitter and rear cells (PERC) consists of at least one laser process and three screen-printing steps followed by the stringing and tabbing of the cells. To reduce the number of steps we have developed a process that metallizes the rear side including contact formation and simultaneously interconnects the cells. We attach an Al foil to an encapsulant layer. By laser processing we form 'laser-fired and bonding contacts' (LFBC) on the passivated rear side of the solar cells. The Al foil contacting the rear is laser welded to the Ag screen-printed front side metallization of the next cell and thus forms the cell interconnection. The laser contacts on the rear show a surface recombination velocity Scont for the contact regions of cm/s and a contact resistivity of 3.52 m?cm2. We present a first proof-of concept module combining the in-laminate Ag-Al laser welding and the LFBC reaching an efficiency of 18.4%. In accelerated aging test modules show no degradation (< 1% in efficiency) after 100 humidity-free cycles.Federal Ministry for Environment, Nature Conservation, and Nuclear Safety/FKZ/0325192State of Lower Saxon

Impact of Ag Pads on the Series Resistance of PERC Solar Cells

Screen-printed passivated emitter and rear cells (PERC) require Ag pads on the rear side to enable solderable connections for module integration. These Ag pads are separated from the silicon by a dielectric layer to avoid recombination of minority charge carriers. The drawback of this configuration is an elongated transport path for the majority charge carriers generated above the pads. This results in an increase in series resistance. The strength of this effect depends on charge carrier generation above the Ag pads that critically depends on shading of the cell's front side. Ag pads are usually wider than the busbars or the interconnector ribbons and thus are only partially shaded. We build PERC test structures with various rear side configurations of Ag and Al screen printing as well as with and without laser contact openings (LCO). Using experiments and finite element simulations we investigate the impact of shading the Ag pads by the busbars and other means. While fully shaded regions do not increase the lumped solar cell's series resistance, unshaded Ag pads lead to an increase of about 37%.German Federal Ministry for Economic Affairs and Energy/032564

Optimizing the Solar Cell Front Side Metallization and the Cell Interconnection for High Module Power Output

Improving the light trapping in a module results in an increase in the generated current. Consequently, an optimization of the front grid metallization of the cell is required for the best trade-off between series resistance, shading, and recombination losses. For this purpose, we combine ray tracing and electrical solar cell and module calculations that explicitly account for cell and module interactions. Our model bases on experimentally verified input parameters: We determine the electrical and optical properties of the front metal fingers of passivated emitter and rear cells (PERC). We show that the effective optical width of the front metal fingers in the module is significantly reduced by 54%. The optimized simulated module has 120 half-size PERC with 20.2% cell efficiency and has an output power of 295.2 W. This is achieved with an increased number of 120 front metal fingers per cell, four white-colored cell interconnection ribbons (CIR), and an increased cell spacing. Applying these optimized design changes to an experimental module we measure a module power output of 294.8 W and a cell-to-module (CTM) factor of 1.02. Measured and simulated power agree and the deviations in Voc, Isc and FF are less than 0.91%rel. We perform a module power gain analysis for the fabricated module and simulate a potential maximum module power of 374.1 W when including further improvements.German Federal Ministry for Economic Affairs and Energy/032564

Two-level Metallization and Module Integration of Point-contacted Solar Cells

AbstractWe present a module integration process for back junction back contact (BJBC) solar cells featuring point contacts to the back surface field (BSF). We apply two metallization layers. A first metal layer of aluminum is deposited onto the rear side of the cell and carries the current extracted from the polarity with the larger surface area fraction, e.g. from the emitter. The second metallization layer is an Al layer on a transparent substrate that we laser-weld to the small and point-shaped regions of the other polarity, e.g. the BSF region. We use a polymer for insulation between the two metal layers. The Al layer on the substrate also serves for cell interconnection, i.e., it enables module integration. Such an interconnection structure halves the fill factor losses due to the metallization. First proof-of-principle modules show a shunt free interconnection, no laser-induced damage, and an energy conversion efficiency of up to 20.7%

Simulation-based roadmap for the integration of poly-silicon on oxide contacts into screen-printed crystalline silicon solar cells

We present a simulation-based study for identifying promising cell structures, which integrate poly-Si on oxide junctions into industrial crystalline silicon solar cells. The simulations use best-case measured input parameters to determine efficiency potentials. We also discuss the main challenges of industrially processing these structures. We find that structures based on p-type wafers in which the phosphorus diffusion is replaced by an n-type poly-Si on oxide junction (POLO) in combination with the conventional screen-printed and fired Al contacts show a high efficiency potential. The efficiency gains in comparsion to the 23.7% efficiency simulated for the PERC reference case are 1.0% for the POLO BJ (back junction) structure and 1.8% for the POLO IBC (interdigitated back contact) structure. The POLO BJ and the POLO IBC cells can be processed with lean process flows, which are built on major steps of the PERC process such as the screen-printed Al contacts and the Al2O3/SiN passivation. Cell concepts with contacts using poly-Si for both polarities (POLO 2-concepts) show an even higher efficiency gain potential of 1.3% for a POLO 2 BJ cell and 2.2% for a POLO 2 IBC cell in comparison to PERC. For these structures further research on poly-Si structuring and screen-printing on p-type poly-Si is necessary. © 2021, The Author(s)

Impact of the contacting scheme on I-V measurements of metallization-free silicon heterojunction solar cells

I-V measurements are sensitive to the number and positioning of current and voltage sensing contacts. For busbarless solar cells, measurement setups have been developed using current collection wires and separate voltage sense contacts. Placing the latter at a defined position enables a grid resistance neglecting measurement and thus I-V characteristics independent from the contacting system. This technique has been developed for solar cells having a finger grid and good conductivity in the direction of the fingers. The optimal position of the sense contact in case of finger-free silicon heterojunction solar cells has not yet been studied. Here, the lateral charge carrier transport occurs in a transparent conductive oxide layer resulting in a higher lateral resistance. We perform finite difference method simulations of HJT solar cells without front metallization to investigate the impact of high lateral resistances on the I-V measurement of solar cells. We show the high sensitivity on the number of used wires for contacting as well as the position of the sense contact for the voltage measurement. Using the simulations, we are able to explain the high difference of up to 7.5% in fill factor measurements of metal free solar cells with varying TCO sheet resistances between two measurement systems using different contacting setups. We propose a method to compensate for the contacting system to achieve a grid-resistance neglecting measurement with both systems allowing a reduction of the FF difference to below 1.5%