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Within this work the impact of contact materials with higher volume resistivity as leaded solder are investigated in terms of comparability of the current conduction through the joint. An approach was developed to experimentally determine the qualitative local current density by magnetic field imaging (MFI) at ribbon-to-ribbon contact samples. The result reveals that the MFI technique on a symmetric sample design allows the evaluation of the current paths in two-dimensional contact areas. Different resistivities of the contact material result in characteristic differences in current distribution through the joint. Low resistive Sn60Pb40-soldererd contacts exhibit localized current injection whereas the tested contact based on electrically conductive adhesives (ECAs) show an extended current flow through the ECA-based contact. A FEM-based simulation model to mimic the used setup was developed and confirmed the results by taking different contact material resistivities into account. For materials with resistivities larger than 1 · 10−3 Ω · cm current injection was found to spread-spatially within the tested contact geometry. Contact material development as well as contact design can benefit from that approach, allowing consumption and material composition optimization. A further advantage is the feasibility of the method to study production failures like inhomogeneous ECA distribution enabling a non-destructive monitoring of process stability and root cause analysis.

According to the International Technology Roadmap for Photovoltaics, passivated emitter and rear solar cells dominate the market in 2021 of up to 80% and are forecast to remain state of the art at least for the next 5 years. Within the production process of solar cells, it is typical to have cells with lower efficiency grades due to variations in manufacturing processes or material defects. Reprocessing such solar cells could save cost due to increased production yield and simultaneously reduced cost for recycling of unusable/unsellable low‐efficiency cells. Herein, the impact of the laser‐enhanced contact optimization (LECO) process on the power output and reliability of solar modules using commercial off‐spec cells of different manufacturers is analyzed. LECO is a downstream process for optimizing metal−semiconductor contacts on finished solar cells. The treatment leads to a significant economic gain due to enhanced cell efficiency (Wp ↑, therefore manufacturing cost per Wp ↓) even of already good solar cells. Herein, the first evaluation of the impact of the LECO process on the cell output power on an industrial scale (>1000 cells) and on module reliability is presented. The results for common short‐term effects like light‐induced degradation and light‐ and elevated temperature‐induced degradation are within expected limits and the durability against, for example, potential‐induced degradation is not changed due to the LECO process. The results further show that cell sorting is crucial for a reliable module and to avoid outliers in terms of unexpected degradation and recovery phenomena of individual cells. [ABSTRACT FROM AUTHOR]