DEK Solar and the Hamelin Institute of Solar Energy (ISFH) joined forces to push the boundaries of crystalline silicon solar cell performance. Their collaboration focused on enhancing efficiency through the use of screen-printed metal contacts on the backside of the cells, combined with a two-step screen and steel mesh printing process on the front. This innovative approach led to a significant breakthrough in PERC (Passivated Emitter and Rear Cell) technology, achieving a record conversion efficiency of 21.2%.
Typically, screen-printed solar cells operate within an efficiency range of 17.5% to 19.5%, but this latest development—leveraging advanced metallization techniques such as screen and stencil printing—has set a new benchmark for PERC cell efficiency. The achievement highlights the potential of cost-effective and scalable manufacturing methods that can drive industry-wide improvements.
Several key technologies from DEK Solar played a critical role in reaching this milestone. These include the high-precision Eclipse metallization platform, ultra-fine grid wire meshes, and precision mesh systems. The battery design incorporated Heraeus-optimized front-side silver paste, while the two-step printing process from DEK Solar enabled precise front metallization. First, the main grid was printed using DEK Solar’s five-grid electrode design, and then the fine grid lines, measuring just 46 μm in width, were applied using the company's ultra-fine grid line stencil.
DEK Solar’s ultra-fine grid stencils ensure exceptional print uniformity and aspect ratio, delivering smooth and consistent fine lines even at widths as narrow as 40 μm. Precise control over the relative heights of the main and fine grids helps reduce shading losses, lower silver paste consumption, and allows the use of non-contact main grid pastes, which improves open-circuit voltage (Voc) and ultimately boosts cell efficiency. The back-side metal contacts were applied using DuPont’s rear aluminum paste.
“This achievement should not be overlooked,†said Tom Falcon, Chief Engineer at DEK Solar. “The joint efforts of ISFH and DEK Solar have delivered a solution that the solar market has been seeking: a cost-effective metallization process using screen and stencil printing to produce highly efficient, industrial-scale PERC cells. This is a major step forward for the global solar industry.â€
Dr. Thorsten Dullweber, head of the ISFH research group on solar cell production processes, also emphasized the significance of the efficiency gain and DEK Solar’s contribution: “Raising efficiency so significantly is no small feat, especially when it’s achieved with less than 80 mg of silver paste per wafer. DEK Solar has been—and will continue to be—an essential partner, offering not only advanced equipment and tools but also deep process expertise.â€
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