SOLARAWARDS2011 SHORTLISTED
solvents. Layers coated with plasmasun® have to feature high conductivity, adhesion (onto Si and Al), solderability.
Problem Solved
The named challenges are solved directly by our new technology. Screenprinters use solvent-based pastes. Using powders plasmasun® is solvent free and thus more green. Pastes are expensive because of a high proportion of silver. We offer more favorable and cheaper microscale metal powders (Ag@Sn / Cu).
This leads to a 50% cost reduction. Thin wafers have to face pressure during screenprinting which means a mechanical stress and can lead to wafer breakage. Our product offers a contact-free metallization and reduces waste rate. After screenprinting the layers have to get dry during fast firing. This step is not necessary with plasmasun®.
Noteworthy
Reinhausen Plasma developed this revolutionary low temperature coating process being the first company to bring a new metallization solution based on
cold.active plasma combined with microscale powders for more efficient and green production to the photovoltaic market. Compared to PVD processes the technology allows in-line metallization under ambient pressure.
Innovation
The plasmasun® system should not be confused with thermal spraying or PVD- sputtering processes. Thermal spraying works with a plasma temperature beyond 10.000°C, with high currents >100A and Granulates D50 around 50µm.
plasmasun® works with D50 around 100nm 20 µm pulsed currents below 10A and heats up the surface of the substrate at an average of 70°C.
This is why the plasma is called cold. PVD solutions are based on vacuum chambers. Generating vacuum is intensive in time, money and in addition slowing down cycle-times. Another advantage of plasmasun® is tin based alloys or copper layers can be directly deposited onto the Al-layer without damaging the cell.
Customer Benefits
Customers benefit from a 50% cost reduction for rearside busbar deposition process compared to screenprinting. They profit from more environmentally sound cell metallization technology. A pre- and aftertreatment, especially fast fining is not needed.
The output of plasmasun® is on the same level as state of the art printers. It can be fully integrated in-line and reduces the footprint compared to screenprinting and drying combination. According to the possibility to deposit directly on the Al- layer there is high potential to gain more efficiency of the cell.
Patents
The following patents had been awarded: Pulverdispergierer DE 102009032908.0-51 Pulverdispergierer INT
PCT/EP2010/059452 Metallisierung DE 102010032187.7 Gepulster Plasmaerzeuger DE 102009015510.4 Gepulster Plasmaerzeuger INT PCT/EP2010/053816.
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www.solar-pv-management.com Issue VII 2011
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