Title: Patterning Metal Grids for GaAs Solar Cells with Cracked Film Lithography: Quantifying the Cost/Performance Tradeoff

Abstract

We introduce cracked film lithography (CFL) as a way to reduce the cost of III–V photovoltaics (PV). We spin-coat nanoparticle suspensions onto GaAs thin-film device stacks. The suspensions dry in seconds, forming crack networks that we use as templates through which to electroplate the solar cells’ front metal grids. For the first time, we show that heating the crack template allows it to flow and refill cracks, which decreases crack footprint and improves final grid transmittance. We demonstrate 24.7%-efficient single-junction GaAs solar cells using vacuum-free CFL grids. These devices are only 1.7% (absolute) less efficient than the baseline grids patterned by photolithography with the loss mostly resulting from the reduced transparency of the CFL pattern. Additional optimization could decrease this difference. Initial cost modeling suggests that CFL is more scalable than photolithography: In particular, CFL’s lower materials and equipment costs could greatly reduce the levelized cost of electricity of III–V PV at scale, a potential step toward terrestrial deployment.

Authors:

Muzzillo, Christopher P.  ^[1];

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• Search DOE PAGES for ORCID "0000-0002-6492-0098"

Wong, Evan ^[1]; Mansfield, Lorelle M. ^[1]; Simon, John ^[1]; Ptak, Aaron J. ^[1]

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+ Show Author Affiliations

1. National Renewable Energy Lab. (NREL), Golden, CO (United States)

Publication Date:

Fri Aug 21 00:00:00 EDT 2020

Research Org.:

National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Org.:

USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Solar Energy Technologies Office

OSTI Identifier:

1665850

Report Number(s):

NREL/JA-5K00-76920
Journal ID: ISSN 1944-8244; MainId:24883;UUID:e0c7c2c9-73bb-4855-8aee-8993cac41186;MainAdminID:18487

Grant/Contract Number:  

AC36-08GO28308

Resource Type:

Accepted Manuscript

Journal Name:

ACS Applied Materials and Interfaces

Additional Journal Information:

Journal Volume: 12; Journal Issue: 37; Journal ID: ISSN 1944-8244

Publisher:

American Chemical Society (ACS)

Country of Publication:

United States

Language:

English

Subject:

14 SOLAR ENERGY; gallium arsenide; photovoltaics; solar cell; electroplating; lithography