Solar Cell Electrode Paste Composition with Multi-Scale Conductive Powders
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Solution Overview
Problem
Existing solar cell electrode paste compositions face challenges in achieving optimal conversion efficiency and processibility due to issues with particle size distribution and viscosity, leading to difficulties in forming high-quality electrodes with improved short circuit current and fill factor.
Innovation Solution
A paste composition comprising a mixture of conductive powders with specific particle diameter and surface area ratios, glass frit, and an organic vehicle, optimized to include 1-10 wt% of a first conductive powder with 1-100 nm diameter and 90-99 wt% of a second conductive powder with 0.5-5 μm diameter, along with a glass frit and organic vehicle, to enhance adhesion, sintering, and viscosity for improved electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional paste compositions are used, then manufacturing process is simple, but conversion efficiency and electrode quality are insufficient
Solution Approach 1:
The patent applies composite materials by combining conductive powders of three different particle size ranges (nanopowder 1-100 nm, submicron powder 0.1-1 μm, and conventional powder 1-5 μm) to create a multi-component conductive powder mixture. This composite structure enables simultaneous achievement of high conversion efficiency through optimized particle packing and adhesion, while maintaining manufacturability through a systematic formulation approach.
2Manufacturing precision
If particle size distribution is not optimized, then paste composition is simple, but short circuit current and fill factor are poor
Solution Approach 1:
The patent applies local quality by assigning different particle size ranges to specific functional roles: nanopowder (1-100 nm) for adhesion enhancement, submicron powder (0.1-1 μm) for filling voids and improving packing density, and conventional powder (1-5 μm) for maintaining structural integrity. This localized functional assignment optimizes short circuit current and fill factor through differentiated particle contributions.
3Ease of operation
If viscosity is not controlled, then paste formulation is simple, but printability and electrode formation are difficult
Solution Approach 1:
The patent applies parameter changes by systematically adjusting the viscosity of the organic vehicle within the range of 50-200 Pa·s through selection of appropriate binders and solvents. This viscosity optimization enables effective screen printing while ensuring proper paste flow and electrode formation, resolving the contradiction between ease of operation and formulation complexity.
Data Source
AI summary
A paste composition for a solar cell electrode includes: a mixture of conductive powders, a glass frit, and an organic vehicle, and the mixture of conductive powders includes about 1 wt % to about 10 wt % of a first conductive powder having an average particle diameter (Dx) from about 1 nm to about 100 nm, and about 90 wt % to about 99 wt % of a second conductive powder having an average particle diameter (D50) from about 0.5 μm to about 5 μm.