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Researchers from Longi and Yangzhou University have developed a laser manufacturing technique that mitigates shock-wave damage in heterojunction back-contact solar cells, achieving a record 27.27% efficiency. This breakthrough could advance ultra-high-efficiency photovoltaic production.
Longi and Yangzhou University have announced the development of a heterojunction back-contact solar cell that achieves a certified efficiency of 27.27%, utilizing a new laser manufacturing process designed to mitigate shock-wave-induced damage. This advancement underscores progress toward ultra-high-efficiency photovoltaic devices and highlights the potential for scalable production methods.
The researchers addressed a key challenge in laser-based manufacturing: shock waves generated during ultrafast laser processing can damage the silicon lattice and passivation layers, reducing device performance and reliability. By identifying the rear-side silicon nitride (SiNx) layer as the primary source of shock-wave amplification, they developed a technique to control and mitigate this damage.
The team discovered that the interaction between ultrafast laser pulses and SiNx causes non-thermal ablation, leading to explosive material ejection and shock wave formation. Experiments comparing cells with and without the rear-side SiNx layer showed that damage was significantly worse when SiNx was present, causing microcracks and loss of passivation. To address this, they engineered a new front-side texture with submicron, rounded-top pyramids, which dispersed stress waves and preserved passivation quality.
The best-performing cell achieved a power conversion efficiency of 27.27%, with an open-circuit voltage of 745.0 mV, a short-circuit current of 7,439 mA, and a fill factor of 86.19%. This performance is close to the record efficiency of 28.13% previously achieved by Longi, confirming the significance of the new manufacturing approach.
Implications for Ultra-High-Efficiency Photovoltaics
This development demonstrates that laser processing, if properly managed, can be integrated into high-efficiency solar cell manufacturing at industrial scales. By reducing laser-induced damage, the new technique enhances device stability, potentially lowering manufacturing costs and improving reliability for commercial applications. Achieving over 27% efficiency in a heterojunction cell marks a step toward more competitive, high-performance solar modules.
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Advances in Laser Manufacturing for PV Cells
Laser processing is increasingly vital in photovoltaic manufacturing, offering precision and throughput advantages. However, high-energy laser pulses can induce shock waves that damage silicon and passivation layers, limiting device performance. Previous efforts to improve laser techniques faced challenges in balancing efficiency and damage mitigation. The recent work by Longi and Yangzhou University builds on ongoing research aimed at overcoming these barriers, with the goal of enabling ultra-high-efficiency cells suitable for commercial deployment.
“Our work not only addresses a major contradiction in laser-based manufacturing but also offers a practical, industry-ready route toward ultra-high-efficiency photovoltaics.”
— an anonymous researcher
laser processed photovoltaic solar cells
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Remaining Questions on Manufacturing Scalability
It is not yet clear how easily this laser processing technique can be scaled for mass production, or how it will perform in long-term operational conditions. Further testing and industry validation are needed to confirm its commercial viability and cost-effectiveness.
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Next Steps Toward Commercial Deployment
Researchers and industry partners are likely to focus on scaling the laser manufacturing process, testing long-term device stability, and integrating the new textures into commercial production lines. Additional efficiency improvements and cost reductions are expected to be explored in ongoing research.
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Key Questions
How does the new laser process improve solar cell efficiency?
The process reduces laser-induced shock wave damage, preserving passivation layers and device structure, which leads to higher efficiency and stability.
Is this technology ready for commercial use?
While promising, further work is needed to scale the process and validate long-term performance before commercial deployment.
How does this efficiency compare to existing solar cells?
The reported 27.27% efficiency is close to the current record of 28.13% achieved by Longi, indicating it is among the highest efficiencies for heterojunction cells.
What are the main technical challenges remaining?
Scaling the laser process, ensuring consistency across large areas, and verifying long-term device stability are key challenges ahead.
Will this method reduce manufacturing costs?
Potentially, by enabling higher throughput and fewer damage-related defects, but cost analysis is still ongoing.
Source: PV Magazine
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