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<p>As aerospace technology advances, the urgent need for cost-effective, scalable space energy solutions has become apparent in constellation satellites. Silicon (Si) solar cells, known for their low cost and satisfying photoelectric conversion efficiency, present a promising low-cost alternative for space energy supplement. This study utilized parallel gap resistance welding (PGRW) to attach silver (Ag) foil made interconnectors to sintered Ag electrodes of Si solar cells, aiming to achieve an optimal solid phase diffusion bonding in the joining interface by carefully controlling the input energy. Compared to the traditional soldering process, the present PGRW technique on one hand possesses outstanding working efficiency, and on the other hand is solder-free which allows the manufactured solar cell panel to serve in more severe temperature changing environment. According to the obtained material characterization and tensile shear test results, the joint achieves an average 45° tensile-shear force of 1.0 N/point when PGRW input energy density is set at 55.70&#xa0;J/mm<sup>2</sup>. The post-welded solar cells also demonstrate exceptional photovoltaic performance, which indicates the fact that the PGRW process has caused no damage to the Si solar cell substrate. During the PGRW process, the sintered Ag layer softens, and the porosity at the electrode joints reduces with increased energy input. The interface between the Ag foil and sintered Ag electrode of the Si solar cell shows a connection by solid-phase element diffusion rather than melting. This finding suggests that PGRW is a promising method for welding sintered Ag paste electrodes, providing critical data support for future space power generation using Si solar cells.</p>

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Achieving Optimal Solid Phase Diffusion Bonding between Silver Foil Interconnector and Sintered Silver Paste Electrode of Silicon Solar Cell via Micro Resistance Spot Welding

  • 期刊论文

  • 发表日期：

    2025年3月19日

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  • Mengjiong Chen,
  • Yuhan Ding,
  • Han Zheng,
  • Chen Shen,
  • Nannan Chen,
  • Xueming Hua

摘要

As aerospace technology advances, the urgent need for cost-effective, scalable space energy solutions has become apparent in constellation satellites. Silicon (Si) solar cells, known for their low cost and satisfying photoelectric conversion efficiency, present a promising low-cost alternative for space energy supplement. This study utilized parallel gap resistance welding (PGRW) to attach silver (Ag) foil made interconnectors to sintered Ag electrodes of Si solar cells, aiming to achieve an optimal solid phase diffusion bonding in the joining interface by carefully controlling the input energy. Compared to the traditional soldering process, the present PGRW technique on one hand possesses outstanding working efficiency, and on the other hand is solder-free which allows the manufactured solar cell panel to serve in more severe temperature changing environment. According to the obtained material characterization and tensile shear test results, the joint achieves an average 45° tensile-shear force of 1.0 N/point when PGRW input energy density is set at 55.70 J/mm2. The post-welded solar cells also demonstrate exceptional photovoltaic performance, which indicates the fact that the PGRW process has caused no damage to the Si solar cell substrate. During the PGRW process, the sintered Ag layer softens, and the porosity at the electrode joints reduces with increased energy input. The interface between the Ag foil and sintered Ag electrode of the Si solar cell shows a connection by solid-phase element diffusion rather than melting. This finding suggests that PGRW is a promising method for welding sintered Ag paste electrodes, providing critical data support for future space power generation using Si solar cells.