Optimization of Infrared Soldering Process to Reduce the Temperature Inhomogeneity in Silicon Solar Cells Using Finite Element Methods

A temperature-controlled infrared soldering process is becoming increasingly crucial for the successful integration of new solar cell technologies, such as silicon heterojunction and perovskite-silicon tandem solar cells. However, optimizing this process remains challenging due to temperature inhomogeneity and difficulties in accurate measurement. In this study, a Finite Element Method model, which can be easily adapted to different solar cell types, sizes and formats, is developed to reduce temperature inhomogeneity by systematically varying key process parameters, including the power supplied to the infrared emitters and the duration of the infrared radiation. A maximum temperature inhomogeneity, ΔTc = 17 K, is achieved for M6 silicon-heterojunction half solar cell, and ΔTc = 15 K, is achieved for M10 silicon-heterojunction half solar cell by identifying the optimum process parameters, which is a significant improvement from ΔTc > 40 K measured from conventional infrared soldering process. Thus, this research improves heating uniformity and minimizes the risk of overheating the solar cells.