Silicon heterojunction back-contact solar cells by laser patterning

Back-contact silicon solar cells, valued for their aesthetic appeal because they have no grid lines on the sunny side, find applications in buildings, vehicles and aircraft and enable self-power generation without compromising appearance1–3. Patterning techniques arrange contacts on the shaded side of the silicon wafer, which offers benefits for light incidence as well. However, the patterning process complicates production and results in power loss. We employed lasers to streamline the fabrication of back-contact solar cells and enhance the power-conversion efficiency. Using this approach, we produced a silicon solar cell that exceeded 27% efficiency. Hydrogenated amorphous silicon layers were deposited onto the wafer for surface passivation and to collect light-generated carriers. A dense passivating contact, which differs from conventional technology practice, was developed. Pulsed picosecond lasers operating at different wavelengths were used to create the back-contact patterns. The approach developed is a streamlined process for producing high-performance back-contact silicon solar cells, with a total effective processing time of about one-third that of the emerging mainstream technology. To meet the terawatt demand, we developed indium-less cells at 26.5% efficiency and precious silver-free cells at 26.2% efficiency. Thus, the integration of solar solutions into buildings and transportation is poised to expand with these technological advances.