Optimization of Laser Fired Contact Process for the Formation of an Al-BSF Layer

The back-surface field (BSF) layer obtained through the laser fired contact (LFC) process is the key to increasing the efficiency of solar cells. In this paper, we studied the optimization of LFC process parameters—focusing on laser frequency, influence, and speed—to achieve good ohmic contacts, and to reduce the heat-affected zone (HAZ). As frequency increases, interactions between the laser and particles increase, with the particles becoming overly heated. This generates the thermal effect, in which heat is transferred to particles not directly affected by the laser—resulting in the HAZ becoming wider and deeper. Under different laser power conditions, depths of approximately 18 and 8.3 μm were observed at laser speeds of 10 and 100 mm/s, respectively. This analysis of performance variables allowed us to identify those best suited to forming an Al-BSF layer approximately 1.2 μm thick, which resulted in the best LFC procedure while minimizing the HAZ area. HAZ size was minimized at a frequency of 400 kHz, using 5 W laser power, and a laser speed of 100 mm/s, while the best cell characteristics were obtained using a laser pitch of 500 μm and a single laser process.