Analyzing the impact of back contact thickness and material type on thermal performance of monocrystalline solar cells

• Thermal modeling of PERC monocrystalline solar cells using COMSOL Multiphysics. • Back-contact materials (Al, Cu, Ag) compared for heat dissipation and performance. • Silver achieved lowest peak temperature (63.7°C), aluminium the highest (75.9°C). • Back-contact thickness showed negligible effect on maximum cell temperature. • Findings guide cost-effective material choice for thermal management in PV cells. A comprehensive numerical analysis of the thermal performance of monocrystalline silicon solar cells was conducted to examine the influence of back-contact material type and thickness. Simulations were performed using the COMSOL Multiphysics package, focusing on three representative materials; aluminum, copper, and silver—selected for their distinct thermal conductivities and relevance in photovoltaic applications. The results show that increasing back-contact thickness from 15 μm to 45 μm produced only a marginal reduction in operating temperature, with a maximum variation of 0.76°C. Conversely, the choice of material exerted a significant effect on thermal behavior. Silver exhibited the most favorable performance, achieving a maximum cell temperature of 63.70°C, while copper offered a slightly higher value of 66.60°C but with improved cost-effectiveness. Aluminum, despite being the most economical option, resulted in the poorest thermal management, with maximum cell temperatures reaching 75.90°C. These findings highlight the importance of back-contact material selection in enhancing thermal stability, efficiency, and lifespan of photovoltaic devices, and provide valuable guidance for the design of sustainable, high-performance solar cells.