Alternative method of making electrical connections in the 1st and 3rd generation modules as an effective way to improve module efficiency and reduce production costs

Abstract

In this work, we propose a new method for manufacturing busbars in photovoltaic modules for different solar cell generations, focusing on 1st and 3rd generations. The method is based on high-pressure spray coating using nanometric metallic powder. Our focus is primarily on opti- mizing conductive paths for applications involving conductive layers used in 3rd generation solar cells, such as quantum dot solar cell, dye-sensitized so- lar cell, and silicon-based solar cells on glass-glass architecture for building integrated photovoltaic. The advantages of the proposed method include the possibility of reducing the material quantity in the conductive paths and creating various shapes on the surface, including bent substrates. This paper examines the influence of the proposed high-pressure spraying technique using metallic particles on the morphology of the resulting conduc- tive paths, interface characteristics, and electrical parameters. Conductive paths were created on four different layers commonly used in photovoltaic systems, including transparent conductive oxide, Cu, Ti, and atomic layer deposition processed Al2O3. The use of high-pressure technology enables the production of conductive layers with strong adhesion to the substrate and precise control of the spatial parameters of conductive paths. Further- more, the temperature recorded during the deposition process does not ex- ceed 385 K, making this technique suitable for various types of substrates, including glass and silicon. Additionally, the produced layers exhibit low resistance, measuring less than 0.3 Ω. Finally, the mechanical resistance, as determined through tearing tests, as well as environmental and time stabil- ity, have been confirmed for the produced paths.