Progress in Cavitated Front Gridline Ag Paste for PERC Solar Cell Architecture

Donald Intal; Sandra Huneycutt; Abasifreke Ebong; Dana Hankey; Marshall Tibbetts

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arXiv · 2610.17341

Progress in Cavitated Front Gridline Ag Paste for PERC Solar Cell Architecture

Donald Intal·Sandra Huneycutt·Abasifreke Ebong·Dana Hankey·Marshall Tibbetts

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Abstract

This paper reports on the progress made with the cavitated silver paste on passivated emitter rear contact cells (PERC) to reduce the series resistance. Thus, electrical and microscopy characterizations are used to examine these resistive losses. Fifteen 252 cm2 PERC cells were fabricated for this assessment. Under standard test conditions, these cells achieved a mean conversion efficiency of 21.87% and a maximum of 22.07%. The mean measured fill factor was 79.98%, compared with a pseudo-fill factor of 83.60%, giving a mean deficit of 3.62 percentage points. Fill factor decreased with increasing area-normalized series resistance, which ranged from 0.53 to 0.83 ohm-cm2, while open-circuit voltage and short-circuit current remained unvaried. These electrical trends support resistive current extraction as the principal contributor to fill-factor variation. Electroluminescence imaging revealed localized emission nonuniformity. Cross-sectional scanning transmission electron microscopy showed variation in the glass interfacial layer, while scanning electron microscopy identified micrometer and sub micrometer silver particles. Conductive atomic force microscopy after sequential removal of the bulk metal and glass revealed spatially heterogeneous current response. These observations are consistent with nonuniform electrical access at the contact, where restricted conducting pathways may concentrate on current and increase local voltage drops. The combined characterization identifies interfacial heterogeneity and the connectivity of conducting pathways as priorities for understanding and reducing extraction losses in cavitated silver metallization.

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Donald Intal, Sandra Huneycutt, Abasifreke Ebong, Dana Hankey, Marshall Tibbetts. 2026-10-12. Progress in Cavitated Front Gridline Ag Paste for PERC Solar Cell Architecture. https://arxiv.org/abs/2610.17341

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