Analysis of cell to module losses and UV radiation hardness for passivated emitter and rear cells and modules

This work presents an experimental analysis and analytical modeling of cell to module losses for passivated emitter and rear cells (PERC), which enables to build a PERC solar module with a record efficiency of 20.2%. Further, it examines the ultraviolet radiation hardness of solar modules employing crystalline silicon (c-Si) solar cells featuring dielectric passivation layers. Passivated emitter and rear cells are on the transition to mass production and expected to become the dominating c-Si solar cell technology in terms of market share in the next few years. Thus, it is of major importance to implement these high efficiency PERC into high efficiency solar modules. When transferring solar cells into a solar module additional recombination, optical, and resistive losses reduce the power of the solar module compared to the power of the solar cell, termed cell to module losses. In this work we study the individual recombination, optical, and resistive characteristics of various cell and module test samples. Based on our experimental results we develop an analytical model that allows to simulate the cell to module losses and reproduces the measurement results of test modules within the measurement uncertainty. We show that a reduction of the cell to module losses requires an adaptation of both, the solar cell as well as the solar module components. We employ the analytical model to improve the cell's front metalization, cell interconnection, light harvesting and cell spacing to reduce the cell to module losses for passivated emitter and rear cells and build an industrial like 60-cell sized solar module with a record power conversion efficiency of 20.2%. Besides the efficiency, the long-term reliability of solar modules is crucial and a performance degradation of new promising technologies can impair their importance for the industry. The application of new metalization pastes that enable to contact lowly doped emitters, increases the spectral response of a PERC in the UV wavelength range. This requires the application of new encapsulation materials with enhanced UV transmittance for PERC solar modules. We report on the UV radiation hardness of solar modules featuring PERC with various silicone nitride passivation layers and employing different encapsulation polymers. Our results reveal that employing polymers with increased UV transparency results in a solar module power loss of 14%. We show that the degradation in module power is due to a reduction of the module's open circuit voltage. This loss is related to an increased charge carrier recombination in the cell, which we ascribe to a degradation of the amorphous silicon nitride (SiN) surface passivation. We develop a novel analytical model to describe the effect of high energetic photons on the solar module performance with a critical energy to deteriorate the surface passivation

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

Increased Light Harvesting by Structured Cell Interconnection Ribbons: An Optical Ray Tracing Study Using a Realistic Daylight Model

A key for increasing the module efficiency is improved light harvesting. The structuring of solar cell interconnection ribbons (CIR) is a promising option for improved light harvesting as it can easily be integrated into current module production. We perform ray tracing simulations of complete PV modules in 3D exhibiting geometric features such as profiled CIR and surface textured cells. We evaluate the increase in module performance by a light harvesting string (LHS) under realistic irradiation conditions with respect to angular and spectral distribution. Using the realistic irradiation for a location in Germany, a location at the polar circle and a location at the equator we simulate the enhancement of short-circuit current density Jsc resulting from the use of LHS. Our results show Jsc gains between 1.00% and 1.86% depending on the location and module orientation. We demonstrate the applicability of our model by comparing measurements and simulations for a one-cell module that we measure and simulate under various angles of the light incidence

PV module current gains due to structured backsheets

We evaluate the optical performance of PV modules with respect to an increase in short circuit current density. Our evaluation is based on the combination of ray tracing simulations and measurements on test modules with four types of backsheets: Two of them are structured, the third is white and diffusively reflecting and the fourth reflects no light. Under normal incidence, structured backsheets reflect incoming light at an angle that causes total internal reflection at the glass/air interface, which guides the light to the solar cell surface. Three different irradiance conditions are studied: a) standard testing conditions (STC) with light incident perpendicular to the module surface, b) variation in the angle of incidence and c) light source with mean annual distribution of angles of incidence. Using the measured refractive index data in ray tracing simulations we find a short circuit current density (Jsc) gain of up to 0.9 mA/cm2 (2.3%) for monofacial cells and a structured backsheet, when compared to a white backsheet with diffuse reflection. For bifacial cells we calculate an even larger Jsc increase of 1.4 mA/cm2 (3.6%). The Jsc increase is larger for bifacial cells, since some light is transmitted through the cells and thus more light interacts with the backsheet. Our optical loss analysis reveals the best performance in STC for edge-aligned Ag grooves. This structure reduces absorption losses from 1.8 mA/cm2 to 0.3 mA/cm and reflection losses from 0.7 mA/cm to 0 mA/cm. This trend also holds under various angles of incidence as confirmed consistently by Jsc measurements and ray racing simulations. Simulations using an annual light source emitting a mean annual distribution of angles of incidence reveal grooves in both orientations edge alignment and east-west alignment achieve similar current gains of up to 1.5% for mono- and of 2.5% for bifacial cells compared to modules with white back sheets. This indicates that for modules with light guiding structures such as these backsheets optimization for STC differs from optimization for annul yield

Optical Constants of UV Transparent EVA and the Impact on the PV Module Output Power under Realistic Irradiation

We measure and discuss the complex refractive index of conventional ethylene vinyl acetate (EVA) and an EVA with enhanced UV-transmission based on spectroscopic ellipsometry, transmission and reflection measurements over the wavelength range from 300-1200 nm. Ray tracing of entire solar cell modules using this optical data predicts a 1.3% increase in short circuit current density (Jsc) at standard test conditions for EVA with enhanced UV transmission. This is in good agreement with laboratory experiments of test modules that result in a 1.4% increase in Jsc by using a UV transparent instead of a conventional EVA. Further, ray tracing simulations with realistic irradiation conditions with respect to angular and spectral distribution reveal an even larger Jsc increase of 1.9% in the yearly average. This increase is largest in the summer months with an increase of up to 2.3%.German Federal Ministry for Economic Affairs and Energy/032564

-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer review by the scientific conference committee of SiliconPV 2016 under responsibility of PSE ScienceDirect Impact of Ag pads on the series resistance of PERC solar cells

Abstract 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%