Towards Commercialization of Low-Cost, Crack-Tolerant, Screen-Printable Metallization by Full-Size Module Testing and Field Characterization

Motivation, Importance, and GoalsThis project is motivated by the need to develop a materials engineering solution to reduce solar module degradation caused by cell cracks.The cell-crack-induced power loss is a long-term degradation mechanism and one of the main causes of solar panel field failures.Cell cracks can occur during module fabrication, transportation, installation, and long-term operation due to thermomechanical stressors.Our team's internal estimation -based on the national weather pattern, frequency of severe weather, and 39-GW asset survey by Heliolytics -reveals that the cell-crack-induced module degradation translates to lost revenues >$17B over an average 5-year period for solar farm owners and to reduced reliability (1.5×  Reduced cell cracks in full-sized solar modules and reduced module degradation rate upon IEC 61215-2:2021 stress testing: mechanical load test (-0.25%) and humidity freeze test (-2.39%)compared to standard commercial metallization (-1.70 % and -3.53% respectively)  Increased cell efficiency by ≥ 0.02% from 21.62% to 21.64% statistically averaged over ∼1000 cells with 83 µm gridline width  Increased cell efficiency by ≥ 0.03% from 22.29 to 23.35% statistically averaged over 60 cells with 40 µm gridline width  Technoeconomic analysis showing a 2.5% increase in net present value (thus "bankability") of utility scale PV farms  Completion of bankability study by Black & Veatch  Engagement with Solamet, Heraeus, and Trina.In summary, we have effectively demonstrated the viability of MetZilla MMC paste through a comprehensive set of tests and validation, ranging from materials-level testing and optimization to mini-module accelerated stress testing, to full-sized module accelerated stress testing in accordance with IEC standards.The MMC metallization is expected to prolong the lifetime of solar modules by reducing cell crack formation and by electrically bridging the cell cracks when cell cracks eventually occur.These benefits translate to increased revenue, increased net present value, and reduced insurance premium for long-term field owners; reduced financial exposure for insurance companies; and reduced price of electricity for consumers.