Filament stretching during micro-extrusion of silver pastes enables an improved fine-line silicon solar cell metallization

The metallization of heterojunction solar cells requires a further reduction of silver consumption to lower production costs and save resources. This article presents how filament stretching of polymer-based low-temperature curing Ag pastes during micro-extrusion enables this reduction while at the same time offering a high production throughput potential. In a series of experiments the relationship between the printing velocity and the filament stretching, thus the reduction of Ag-electrode widths and Ag laydown is evaluated. Furthermore, an existing filament stretching model for the parallel dispensing process is advanced further and utilized to calculate the elongational viscosity. The stretching effect enables a reduction of the Ag-electrode width by down to Δw(f) = − 40%(rel.) depending on the nozzle diameter and paste type. The Ag laydown has been reduced from m(Ag,cal.) = 0.84 mg per printed line to only m(Ag,cal.) = 0.54 mg per printed Ag-electrode when 30 µm nozzle openings are used, demonstrating the promising potential of parallel dispensing technology for the metallization of silicon heterojunction solar cells.