Optimization of multi-layer front-contact grid patterns for solar cells

In a front-contact grid pattern for a solar cell there is a trade-off necessary between shadowing loss and excessive power loss due to voltage drop in the metalization itself. If the metalization is too little there may be excessive contact resistance to the underlying semiconductor and insufficient coverage to control losses in the thin front-surface layer of the solar cell. Optimization of grid pattern area and geometry is considered analytically to minimize total losses. Worthwhile performance advantages are shown to be possible, particularly in concentrator systems, if multi-layer grid patterns are used. The current carrying fingers should be approximately square in metal cross section and the main current feedout bars should not only be wider but also thicker than the primary collecting fingers. This is termed multi-level metalization. Effective use of multi-level grid metalization allows much greater concentration-to-loss ratio for a cell of large area and permits good performance from cells of high front-layer sheet resistance.