Optimization strategies for metallization in n-type crystalline silicon TOPCon solar cells: Pathways to elevated fill factor and enhanced efficiency

In advancing photovoltaic technology, optimizing the metallization process is crucial for balancing electrical conductivity and optical performance in solar cell fabrication. This process directly impacts the efficiency and quality of solar cells, traditionally measured by the fill factor (FF). Historically, efforts have focused on evolving metal contacts to reduce optical shading and series resistance, which degrade solar cell efficiency. Our study enhances n-type Tunnel Oxide Passivated Contact (n-TOPCon) solar cells by optimizing screen-printing metallization, particularly by examining the effects of squeegee speeds. Employing a mix of experimental and analytical methodologies, we aimed to identify optimal conditions that improve electrical and optical performance, thereby elevating cell efficiency. Our findings indicate that a squeegee speed of 170 mm/s substantially boosts solar cell performance, evidenced by a current density (J_sc) of 38.96 mA/cm², open-circuit voltage (V_oc) of 684.29 mV, fill factor (FF) of 78.77 %, and a power conversion efficiency (PCE) of 21.00 %. Further, dark I–V measurements confirmed a shunt resistance (R_sh) of 6.25 × 10⁶ Ω and a reduced series resistance (R_s) of 6.48 Ω, underscoring the significance of precise metallization in reducing resistive losses and enhancing efficiency. Future research will explore innovative materials and cutting-edge printing techniques beyond squeegee speed adjustments. The potential incorporation of nanomaterials and conducting polymers aims to refine the metallization process further, promising to push the boundaries of efficiency and cost-effectiveness. This progression is essential for advancing n-TOPCon solar cell development, setting new industry standards, and propelling the sustainable energy movement.