Nano-metal connections for a solar cell array
An electrical connection is formed between first and second conductive elements, by inserting a nano-metal material between the first and second conductive elements; and heating the nano-metal material to a melting temperature to form the electrical connection between the first and second conductive elements. The nano-metal material may comprise a nano-metal paste or ink comprised of one or more of Gold (Au), Copper (Cu), Silver (Ag), and/or Aluminum (Al) nano-particles that melt or fuse into a solid to form the electrical connection, at a melting temperature of about 150-250 degrees C., and more preferably, about 175-225 degrees C. The electrical connection may be formed between a solar cell and a substrate by creating a via in the solar cell between a front and back side of the solar cell, wherein the via is connected to a contact on the front side of the solar cell and a trace on the substrate.
1. A method, comprising:
forming an electrical connection between a solar cell and a substrate on which the solar cell is attached using first and second conductive elements, wherein the first and second conductive elements are comprised of Silver (Ag), comprising:
inserting a nano-metal material between the first and second conductive elements, wherein the nano-metal material comprises a nano-metal paste or ink comprised of at least Ag nano-particles that melt into a solid to form the electrical connection; and melting the nano-metal paste or ink comprised of the at least Ag nanoparticles into a solid to form the electrical connection between the first and second conductive elements.
2. The method of claim 1 , wherein the first and second conductive elements comprise a metal foil interconnect and a surface layer on the substrate.
3. The method of claim 2 , wherein the surface layer is a plated surface layer.
4. The method of claim 1 , wherein the first and second conductive elements comprise a metal foil interconnect and a front or back contact on the solar cell.
5. The method of claim 1 , wherein the nano-metal paste or ink is further comprised of one or more of Gold (Au), Copper (Cu), and Aluminum (Al) nanoparticles that melt into a solid to form the electrical connection.
6. The method of claim 5 , wherein the nano-particles have sizes less than about 100 nm.
7. The method of claim 5 , wherein the nano-particles have sizes in a range of about 0.5-10 nm.
8. The method of claim 5 , wherein the nano-metal material comprises Ag and Au, Cu, or Al nano-particles placed between the first and second conductive elements comprised of Ag.
9. The method of claim 1 , wherein the nano-metal material has a melting or solidification temperature of about 150-250 degrees C.
10. The method of claim 1 , wherein the nano-metal material has a melting or solidification temperature of about 175-225 degrees C.
11. The method of claim 1 , wherein the nano-metal material is not an alloy.
12. An article, comprising:
an electrical connection formed between a solar cell and a substrate on which the solar cell is attached using first and second conductive elements, wherein the first and second conductive elements are comprised of Silver (Ag), comprising:
a nano-metal material inserted between the first and second conductive elements, wherein the nano-metal material comprises a nano-metal paste or ink comprised of at least Ag nano-particles that melt or fuse into a solid to form the electrical connection;
wherein the nano-metal material is a melted nano-metal paste or ink comprised of the at least Ag nano-particles that are melted into a solid that forms the electrical connection between the first and second conductive elements.
13. The article of claim 12 , wherein the first and second conductive elements comprise a metal foil interconnect and a surface layer on the substrate.
14. The article of claim 13 , wherein the surface layer is a plated surface layer.
15. The article of claim 12 , wherein the first and second conductive elements comprise a metal foil interconnect and a front or back contact on the solar cell.
16. The article of claim 12 , wherein the nano-metal paste or ink is further comprised of one or more of Gold (Au), Copper (Cu), and Aluminum (Al) nano-particles that melt into a solid to form the electrical connection.
17. The article of claim 16 , wherein the nano-particles have sizes less than about 100 nm.
18. The article of claim 16 , wherein the nano-particles have sizes in a range of about 0.5-10 nm.
19. The article of claim 16 , wherein the nano-metal material comprises Ag and Au, Cu, or Al nano-particles placed between the first and second conductive elements comprised of Ag.
20. The article of claim 12 , wherein the nano-metal material has a melting or solidification temperature of about 150-250 degrees C.
21. The article of claim 12 , wherein the nano-metal material has a melting or solidification temperature of about 175-225 degrees C.
22. The article of claim 12 wherein the nano-metal material is not an alloy.