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Al-Foil on Encapsulant for the Interconnection of Al-Metalized Silicon Solar Cells

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6 Author(s)
Henning Schulte-Huxel ; Institute for Solar Energy Research Hamelin, D-31860 Emmerthal, Germany ; Susanne Blankemeyer ; Robert Bock ; Agnes Merkle
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We demonstrate the interconnection of silicon solar cells with evaporated aluminum back contacts using an aluminum foil which is attached to a silicone encapsulant. The aluminum-based mechanical and electrical laser interconnection (AMELI) process forms laser weld spots using single laser pulses. These laser welds resist high mechanical stresses and have a low electrical contact resistivity. No solder, conductive adhesives, or Ag-pastes are required for interconnection. We find the electrical contact resistivity to be below ρc = 0.01 mΩ·cm2. The contact resistance is constant under accelerated aging of 300 humidity-freeze cycles. With a tensile testing machine, we measure tear-off stresses in the perpendicular direction of up to 380 kPa for our laser weld spots. We present a proof-of-concept module which consists of five n-type back-junction back-contact solar cells with a conversion efficiency of 20.4%. The unchanged fill factor FF and open circuit voltage Voc verify a damage- and loss-free interconnection which is supported by electroluminescence measurements.

Published in:

IEEE Journal of Photovoltaics  (Volume:3 ,  Issue: 1 )