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Laser Soldering method Of Solar Cells
:: 08 October, 2007
A single solar cell produces a relatively low output – it’s a case of strength in numbers. Tiny strips of metal are used to link cells together. If the laser soldering temperature is too high, the solder joint may fracture. A new system provides automatic temperature regulation.
Teamwork is what matters – even in the case of solar cells: To obtain sufficient power to operate a pocket calculator, parking ticket dispenser or photovoltaic module, sunlight has to be captured simultaneously by an array of cells. They are connected in series using tiny strips of metal known as stringers. Each stringer has to be positioned in precisely the right spot, then its solder coating is melted using a hot electrode. When the solder sets, it forms a stable bond with the metallic coating on the silicon. The amount of heat induced in the stringer and the silicon depends on the contact between the soldering electrode and the stringer. Applying too much energy causes thermal stress which in the worst case could destroy the solder joint, leaving a break in the electrical circuit that makes the solar module unfit for use.
Researchers at the Fraunhofer Institute for Laser Technology ILT in Aachen have developed a non-contact soldering system in which the temperature is constantly monitored. If the temperature deviates beyond set limits, the system automatically adjusts it to an acceptable value. “Instead of an electrode, we use a laser beam for the soldering operation,” says ILT department head Dr. Arnold Gillner. “To melt the solder, we pass a laser beam over the solder-coated stringer. An infrared heat camera derives the temperature of the silicon and of the metal strip from real-time measurements of their emitted radiant heat. If the temperature is too high or too low, a feedback control circuit automatically adapts the laser output within milliseconds.” The system is already in use for industrial surface engineering applications. Solar applications could be on the market in a year or so.
The researchers’ next project is to develop a faster, more reliable method of connecting solar cells by means of laser welding. “Whereas soldering only involves melting the solder, in laser welding the stringer itself is melted,” explains Gillner. This means applying more heat than for soldering, but only for a very short time. “Since the laser is only in contact with the materials for a brief instant, only a small amount of energy is transferred to the materials despite the higher temperature – resulting in even fewer heat-induced defects,” he adds. What complicates the matter is the fact that the stringer has a diameter of about 200 micrometers, whereas the metallic coating on the silicon required to conduct electricity has a thickness of a mere 10 micrometers. The laser beam has to be modulated in such a way that the stringer will melt while leaving the coating on the silicon intact.
News inside news:
Solar cell
A solar cell or photovoltaic cell is a device that converts light energy into electrical energy. Sometimes the term solar cell is reserved for devices intended specifically to capture energy from sunlight, while the term photovoltaic cell is used when the light source is unspecified.
Fundamentally, the device needs to fulfill only two functions: photogeneration of charge carriers (electrons and holes) in a light-absorbing material, and separation of the charge carriers to a conductive contact that will transmit the electricity (simply put, carrying electrons off through a metal contact into a wire or other circuit). This conversion is called the photovoltaic effect, and the field of research related to solar cells is known as photovoltaics.
Solar cells have many applications. They have long been used in situations where electrical power from the grid is unavailable, such as in remote area power systems, Earth-orbiting satellites and space probes, consumer systems, e.g. handheld calculators or wrist watches, remote radiotelephones and water pumping applications. More recently, solar cells are starting to be used in assemblies of solar modules (photovoltaic arrays) connected to the electricity grid through an inverter, often in combination with a net metering arrangement.
Four generations of development
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First
The first generation photovoltaic, consists of a large-area, single layer p-n junction diode, which is capable of generating usable electrical energy from light sources with the wavelengths of sunlight. These cells are typically made using a silicon wafer. First generation photovoltaic cells (also known as silicon wafer-based solar cells) are the dominant technology in the commercial production of solar cells, accounting for more than 86% of the solar cell market.
Second
The second generation of photovoltaic materials is based on the use of thin-film deposits of semiconductors. These devices were initially designed to be high-efficiency, multiple junction photovoltaic cells. Later, the advantage of using a thin-film of material was noted, reducing the mass of material required for cell design. This contributed to a prediction of greatly reduced costs for thin film solar cells. There are currently (2007) a number of technologies/semiconductor materials under investigation or in mass production. Examples include Amorphous silicon, Polycrystalline silicon, micro-crystalline silicon, Cadmium telluride, copper indium selenide/sulfide. Typically, the efficiencies of thin-film solar cells are lower compared with silicon (wafer-based) solar cells, but manufacturing costs are also lower, so that a lower cost per watt can be achieved. Another advantage of the reduced mass is that less support is needed when placing panels on rooftops and it allows fitting panels on light or flexible materials, even textiles.
Third
Third generation photovoltaics are very different from the previous semiconductor devices as they do not rely on a traditional p-n junction to separate photogenerated charge carriers. These new devices include photoelectrochemical cells, polymer solar cells, and nanocrystal solar cells. Dye-sensitized solar cells are now in production.
Fourth
Fourth generation Composite photovoltaic technology with the use of polymers with nano particles can be mixed together to make a single multispectrum layer. Then the thin multi spectrum layers can be stacked to make multispectrum solar cells more efficient and cheaper based on polymer solar cell and multi junction technology used by NASA on Mars missions. The layer that converts different types of light is first, then another layer for the light that passes and last is an infra-red spectrum layer for the cell - thus converting some of the heat for an overall solar cell composite.
Companies working on fourth generation photovoltaics include Xsunx, Konarka Technologies, Inc., Nanosolar, Dyesol and Nanosys. Research is also being done in this area by the USA's National Renewable Energy Laboratory (http://www.nrel.gov/).
History
Main article: Timeline of solar cells
The term "photovoltaic" comes from the Greek φώς:phos meaning "light", and "voltaic", meaning electrical, from the name of the Italian physicist Volta, after whom the measurement unit volts are named. The term "photo-voltaic" has been in use in English since 1849.
The photovoltaic effect was first recognised in 1839 by French physicist Alexandre-Edmond Becquerel. However, it was not until 1883 that the first solar cell was built, by Charles Fritts, who coated the semiconductor selenium with an extremely thin layer of gold to form the junctions. The device was only around 1% efficient. Russell Ohl patented the modern solar cell in 1946 (U.S. Patent 2,402,662 , "Light sensitive device"). Sven Ason Berglund had a prior patent concerning methods of increasing the capacity of photosensitive cells. The modern age of solar power technology arrived in 1954 when Bell Laboratories, experimenting with semiconductors, accidentally found that silicon doped with certain impurities was very sensitive to light.
This resulted in the production of the first practical solar cells with a sunlight energy conversion efficiency of around 6 percent. This milestone created interest in producing and launching a geostationary communications satellite by providing a viable power supply. Russia launched the first artificial satellite in 1957, and the United States' first artificial satellite was launched in 1958. Russian Sputnik 3 ("Satellite-3"), launched on 15 May 1958, was the first satellite to use solar arrays. This was a crucial development which diverted funding from several governments into research for improved solar cells.
In 1970 first highly effective GaAs heterostructure solar cells were created by Zhores Alferov and his team in the USSR.
Applications and implementations
Polycrystaline PV cells laminated to backing material in a PV module
Polycrystalline PV cellsMain article: photovoltaic array
Solar cells are often electrically connected and encapsulated as a module. PV modules often have a sheet of glass on the front (sun up) side , allowing light to pass while protecting the semiconductor wafers from the elements (rain, hail, etc.). Solar cells are also usually connected in series in modules, creating an additive voltage. Connecting cells in parallel will yield a higher current. Modules are then interconnected, in series or parallel, or both, to create an array with the desired peak DC voltage and current.
The power output of a solar array is measured in watts or kilowatts. In order to calculate the typical energy needs of the application, a measurement in watt-hours, kilowatt-hours or kilowatt-hours per day is often used. A rule of thumb commonly used is that peak power times 20% gives average power, equating to one kW peak producing 4.8 kWh per day.
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Tags: Laser , Soldering , Solar Cell , stringers , sunlight , Fraunhofer Institute for Laser Technology , non-contact soldering system , temperature , laser beam , Dr. Arnold Gillner , laser welding. ,
